U.S. patent application number 17/478574 was filed with the patent office on 2022-02-03 for aerosol delivery system.
The applicant listed for this patent is Nerudia Limited. Invention is credited to Ben ASTBURY, Ben ILLIDGE, Chris LORD, Alfred MADDEN, Thomas SUDLOW.
Application Number | 20220030942 17/478574 |
Document ID | / |
Family ID | |
Filed Date | 2022-02-03 |
United States Patent
Application |
20220030942 |
Kind Code |
A1 |
LORD; Chris ; et
al. |
February 3, 2022 |
AEROSOL DELIVERY SYSTEM
Abstract
There is disclosed an aerosol-generation apparatus having a
heater and a fluid-transfer article, the fluid-transfer article
including a first region holding an aerosol precursor and
transferring said aerosol precursor to an activation surface of a
second region of said article, the activation surface being
disposed at an end of the article configured for thermal
interaction with a heating surface of the heater. The activation
surface has at least one channel therein and is configured such
that, when the fluid transfer article is arranged with respect to
the heating surface for thermal interaction therebetween, the
channel(s) opposes the heating surface and opens towards said
heating surface. The heater has a substrate forming the heating
surface and at least one heating element on a part of that heating
surface. The channel(s) opposes a part of the heating surface other
than part of the heating surface on which the heating element is
formed.
Inventors: |
LORD; Chris; (Liverpool,
GB) ; SUDLOW; Thomas; (Liverpool, GB) ;
ILLIDGE; Ben; (Liverpool, GB) ; MADDEN; Alfred;
(Liverpool, GB) ; ASTBURY; Ben; (Liverpool,
GB) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Nerudia Limited |
Liverpool |
|
GB |
|
|
Appl. No.: |
17/478574 |
Filed: |
September 17, 2021 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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PCT/EP2020/057314 |
Mar 17, 2020 |
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17478574 |
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PCT/EP2020/057352 |
Mar 17, 2020 |
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PCT/EP2020/057314 |
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PCT/EP2020/057288 |
Mar 17, 2020 |
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PCT/EP2020/057352 |
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PCT/EP2020/057332 |
Mar 17, 2020 |
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PCT/EP2020/057288 |
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PCT/EP2020/057343 |
Mar 17, 2020 |
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PCT/EP2020/057332 |
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PCT/EP2020/057320 |
Mar 17, 2020 |
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PCT/EP2020/057343 |
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PCT/EP2020/057339 |
Mar 17, 2020 |
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PCT/EP2020/057320 |
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PCT/EP2020/057303 |
Mar 17, 2020 |
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PCT/EP2020/057339 |
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PCT/EP2020/057316 |
Mar 17, 2020 |
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PCT/EP2020/057303 |
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PCT/EP2020/057310 |
Mar 17, 2020 |
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PCT/EP2020/057316 |
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PCT/EP2020/057331 |
Mar 17, 2020 |
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PCT/EP2020/057310 |
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International
Class: |
A24F 40/44 20060101
A24F040/44; A24F 40/10 20060101 A24F040/10; A24F 40/46 20060101
A24F040/46; A24F 40/42 20060101 A24F040/42; A24F 40/485 20060101
A24F040/485; A24F 40/70 20060101 A24F040/70 |
Foreign Application Data
Date |
Code |
Application Number |
Mar 21, 2019 |
EP |
19164440.0 |
Mar 21, 2019 |
EP |
19164447.5 |
Mar 21, 2019 |
EP |
19164448.3 |
Mar 21, 2019 |
EP |
19164454.1 |
Mar 21, 2019 |
EP |
19164457.4 |
Mar 21, 2019 |
EP |
19164458.2 |
Mar 21, 2019 |
EP |
19164461.6 |
Mar 21, 2019 |
EP |
19164462.4 |
Mar 21, 2019 |
EP |
19164465.7 |
Mar 21, 2019 |
EP |
19164466.5 |
Mar 21, 2019 |
EP |
19164474.9 |
Claims
1. An aerosol-generation apparatus comprising a heater and a
fluid-transfer article, said fluid-transfer article having a first
region for holding an aerosol precursor and for transferring said
aerosol precursor to an activation surface of a second region of
said article, said activation surface being disposed and configured
for thermal interaction with a heating surface of said heater; said
second region comprising at least one discontinuity in said
activation surface to form a corresponding at least one channel
between said second region and said heating surface and being
configured such that, when the fluid transfer article is arranged
with respect to said heating surface of the heater for thermal
interaction therebetween, the or each channel opposes said heating
surface, opens towards said heating surface, and provides an
air-flow pathway across said heating surface; wherein the heater
comprises a substrate defining said heating surface, and at least
one heating element formed on a part of said heating surface, and
said at least one channel opposes a further part of said heating
surface other than said part of said heating surface on which said
heating element is formed.
2. An aerosol-generation apparatus according to claim 1, wherein
said activation surface is configured such that the or each said
discontinuity is spaced apart from said heating surface.
3. An aerosol-generation apparatus according to claim 1, wherein
the or each said channel is at least partly defined by a pair of
spaced apart side walls, and an arcuate surface portion extending
between said wall portions to form a ceiling portion of said
channel.
4. An aerosol-generation apparatus according to claim 3, wherein
said arcuate surface portion blends smoothly with each of said side
walls, thereby eliminating a sharp corner therebetween.
5. An aerosol-generation apparatus according to claim 1, wherein
the or each channel is at least partially defined by a pair of
spaced apart side walls and a flat surface portion, said flat
surface portion extending between said wall portions to form a
ceiling portion of said channel.
6. An aerosol-generation apparatus according to claim 1, wherein
the or each channel is at least partially defined by a pair of side
walls, said side walls being inclined relative to each other to
meet at an apex portion of said channel.
7. An aerosol-generation apparatus according to claim 3, wherein
said side walls are substantially planar.
8. An aerosol-generation apparatus according to claim 1, wherein at
least said second region is formed from a polymeric wicking
material.
9. An aerosol-generation apparatus according to claim 8, wherein
said first and second regions are both formed from said polymeric
wicking material.
10. An aerosol-generation apparatus according to claim 8, wherein
said polymeric wicking material is porous.
11. An aerosol-generation apparatus according to claim 8, wherein
said polymeric wicking material is configured such that the pore
diameter in said first region is greater than the pore diameter in
said second region.
12. An aerosol-generation apparatus according to claim 8, wherein
said polymeric wicking material is heat resistant.
13. An aerosol-generation apparatus according to claim 8, wherein
said polymeric wicking material is a hydrophilic material that is
configured to transfer fluid from said first region to said second
region.
14. An aerosol-generation apparatus according to claim 8, wherein
said polymeric wicking material is of greater hydrophilicity in
said second region than said first region.
15. An aerosol delivery system comprising an aerosol-generation
apparatus according to claim 1, and a carrier, the carrier having a
housing containing said heater and said fluid-transfer article.
16. An aerosol delivery system according to claim 14, wherein said
housing has an inlet and an outlet, said air-flow pathway extending
to said inlet and said outlet.
17-167. (canceled)
Description
CROSS REFERENCE TO RELATED APPLICATIONS/INCORPORATION BY REFERENCE
STATEMENT
[0001] This application is a non-provisional application claiming
benefit to the international application no. PCT/EP2020/57288 filed
on Mar. 17, 2020, which claims priority to EP 19164447.5 filed on
Mar. 21, 2019. This application also claims benefit to the
international application no. PCT/EP2020/57303 filed on Mar. 17,
2020, which claims priority to EP 19164454.1 filed on Mar. 21,
2019. This application also claims benefit to the international
application no. PCT/EP2020/57310 filed on Mar. 17, 2020, which
claims priority to EP 19164457.4 filed on Mar. 21, 2019. This
application also claims benefit to the international application
no. PCT/EP2020/57314 filed on Mar. 17, 2020, which claims priority
to EP 19164440.0 filed on Mar. 21, 2019. This application also
claims benefit to the international application no.
PCT/EP2020/57316 filed on Mar. 17, 2020, which claims priority to
EP 19164466.5 filed on Mar. 21, 2019. This application also claims
benefit to the international application no. PCT/EP2020/57320 filed
on Mar. 17, 2020, which claims priority to EP 19164458.2 filed on
Mar. 21, 2019. This application also claims benefit to the
international application no. PCT/EP2020/57331 filed on Mar. 17,
2020, which claims priority to EP 19164461.6 filed on Mar. 21,
2019. This application also claims benefit to the international
application no. PCT/EP2020/57332 filed on Mar. 17, 2020, which
claims priority to EP 19164462.4 filed on Mar. 21, 2019. This
application also claims benefit to the international application
no. PCT/EP2020/57339 filed on Mar. 17, 2020, which claims priority
to EP 19164474.9 filed on Mar. 21, 2019. This application also
claims benefit to the international application no.
PCT/EP2020/57343 filed on Mar. 17, 2020, which claims priority to
EP 19164448.3 filed on Mar. 21, 2019. This application also claims
benefit to the international application no. PCT/EP2020/57352 filed
on Mar. 17, 2020, which claims priority to EP 19164465.7 filed on
Mar. 21, 2019. The entire contents of each of the above referenced
applications are hereby incorporated herein by reference in their
entirety.
FIELD OF THE DISCLOSURE
[0002] The present disclosure relates to an aerosol delivery system
and an aerosol-generation apparatus for an aerosol delivery system.
In particular, the present disclosure relates to an aerosol
delivery system including a heater configured to heat an aerosol
precursor to generate an aerosolized composition for inhalation by
a user, and to an aerosol-generation apparatus therefor.
[0003] The present disclosure also relates to a fluid transfer
article. In particular, the present disclosure relates to a fluid
transfer article having a precursor with a viscosity profile such
that it is retained in the fluid transfer article at 25.degree. C.
and may be drawn from the fluid transfer article when there is a
lower pressure external to the fluid transfer article at higher
temperatures.
BACKGROUND
[0004] Pharmaceutical medicament, physiologically active substances
and flavorings for example may be delivered to the human body by
inhalation through the mouth and/or nose. Such material or
substances may be delivered directly to the mucosa or mucous
membrane lining the nasal and oral passages and/or the pulmonary
system. For example, nicotine is consumed for therapeutic or
recreational purposes and may be delivered to the body in a number
of ways. Nicotine replacement therapies are aimed at people who
wish to stop smoking and overcome their dependence on nicotine.
Nicotine is delivered to the body in the form of aerosol delivery
devices and systems, also known as smoking-substitute devices or
nicotine delivery devices. Such devices may be non-powered or
powered.
[0005] Devices or systems that are non-powered may comprise
nicotine replacement therapy devices such as "inhalators", e.g.,
Nicorette.RTM. Inhalator. These generally have the appearance of a
plastic cigarette and are used by people who crave the behavior
associated with consumption of combustible tobacco--the so-called
hand-to-mouth aspect--of smoking tobacco. Inhalators generally
allow nicotine-containing aerosol to be inhaled through an elongate
tube in which a container containing a nicotine carrier, for
example, a substrate, is located. An air stream caused by suction
through the tube by the user carries nicotine vapors into the lungs
of the user to satisfy a nicotine craving. The container may
comprise a replaceable cartridge, which includes a cartridge
housing and a passageway in the housing in which a nicotine
reservoir is located. The reservoir holds a measured amount of
nicotine in the form of the nicotine carrier. The measured amount
of nicotine is an amount suitable for delivering a specific number
of "doses". The form of the nicotine carrier is such as to allow
nicotine vapor to be released into a fluid stream passing around or
through the reservoir. This process is known as aerosolization and
or atomization. Aerosolization is the process or act of converting
a physical substance into the form of particles small and light
enough to be carried on the air, i.e., into an aerosol. Atomization
is the process or act of separating or reducing a physical
substance into fine particles and may include the generation of
aerosols. The passageway generally has an opening at each end for
communication with the exterior of the housing and for allowing the
fluid stream through the passageway. A nicotine-impermeable barrier
seals the reservoir from atmosphere. The barrier includes
passageway barrier portions for sealing the passageway on both
sides of the reservoir. These barrier portions are frangible so as
to be penetrable for opening the passageway to atmosphere.
[0006] A device or a system that is powered can fall into two
sub-categories. In both subcategories, such devices or systems may
comprise electronic devices or systems that permit a user to
simulate the act of smoking by producing an aerosol mist or vapor
that is drawn into the lungs through the mouth and then exhaled.
The electronic devices or systems typically cause the vaporization
of a liquid containing nicotine and entrainment of the vapor into
an airstream. Vaporization of an element or compound is a phase
transition from the liquid phase to vapor, i.e., evaporation or
boiling. In use, the user experiences a similar satisfaction and
physical sensation to those experienced from a traditional smoking
or tobacco product, and exhales an aerosol mist or vapor of similar
appearance to the smoke exhaled when using such traditional smoking
or tobacco products. A person of ordinary skill in the art will
appreciate that devices or systems of the second, powered category
as used herein include, but are not limited to, electronic nicotine
delivery systems, electronic cigarettes, e-cigarettes, e-cigs,
vaping cigarettes, pipes, cigars, cigarillos, vaporizers and
devices of a similar nature that function to produce an aerosol
mist or vapor that is inhaled by a user. Such nicotine delivery
devices or systems of the second category incorporate a liquid
reservoir element generally including a vaporizer or misting
element such as a heating element or other suitable element, and
are known, inter alia, as atomizers, cartomizers, or clearomizers.
Some electronic cigarettes are disposable; others are reusable,
with replaceable and refillable parts.
[0007] Aerosol delivery devices or systems in a first sub-category
of the second, powered category generally use heat and/or
ultrasonic agitation to vaporize a solution comprising nicotine
and/or other flavoring, propylene glycol and/or glycerin-based base
into an aerosol mist of vapors for inhalation.
[0008] Aerosol delivery devices or systems in a second sub-category
of the second, powered category may typically comprise devices or
systems in which tobacco is heated rather than combusted. During
use, volatile compounds may be released from the tobacco by heat
transfer from the heat source and entrained in air drawn through
the aerosol delivery device or system. Direct contact between a
heat source of the aerosol delivery device or system and the
tobacco heats the tobacco to form an aerosol. As the aerosol
containing the released compounds passes through the device, it
cools and condenses to form an aerosol for inhalation by the user.
In such devices or systems, heating, as opposed to burning, the
tobacco may reduce the odor that can arise through combustion and
pyrolytic degradation of tobacco.
[0009] Aerosol delivery devices or systems falling into the first
sub-category of powered devices or systems may typically comprise a
powered unit, comprising a heater element, which is arranged to
heat a portion of a carrier that holds an aerosol precursor. The
carrier comprises a substrate formed of a "wicking" material, which
can absorb aerosol precursor liquid from a reservoir and hold the
aerosol precursor liquid. Upon activation of the heater element,
aerosol precursor liquid in the portion of the carrier in the
vicinity of the heater element is vaporized and released from the
carrier into an airstream flowing around the heater and carrier.
Released aerosol precursor is entrained into the airstream to be
borne by the airstream to an outlet of the device or system, from
where it can be inhaled by a user.
[0010] Typical aerosol precursors for aerosol delivery devices
contain one or more solvents, and optionally one or more active
ingredients and one or more additives. The one or more solvents are
typically at least one non-aqueous solvent selected from one or
both of a glycol and a glycerin. Typical active ingredients are
nicotine and caffeine. Typical additives are scents, flavorings,
colorings or efficacy enhancers.
[0011] Upon heating an aerosol precursor, the non-aqueous solvents
therein form aerosol particles which the one or more active
ingredients or one or more additives are bound to or dissolved in.
The aerosol particles carry the one or more active ingredients or
additives into the respiratory system of the user on inhalation.
Setting the heating element to a lower temperature vaporizes the
aerosol precursors to form a cooler, less dense aerosol cloud
whereas setting the heating element to a higher temperature
provides warmer, thicker aerosol clouds. Upon pulmonary
administration, the one or more active ingredients bypass acid and
bile in the stomach for expedited effect upon the central nervous
system.
[0012] The heater element is typically a resistive coil heater,
which is wrapped around a portion of the carrier and is usually
located in the liquid reservoir of the device or system.
Consequently, the surface of the heater may always be in contact
with the aerosol precursor liquid, and long-term exposure may
result in the degradation of either or both of the liquid and
heater. Furthermore, residues may build up upon the surface of the
heater element, which may result in undesirable toxicants being
inhaled by the user. Furthermore, as the level of liquid in the
reservoir diminishes through use, regions of the heater element may
become exposed and overheat.
[0013] A smoking-substitute device is an electronic device that
permits the user to simulate the act of smoking by producing an
aerosol mist or vapor that is drawn into the lungs through the
mouth and then exhaled. The inhaled aerosol mist or vapor typically
bears nicotine and/or other flavorings without the odor and health
risks associated with traditional smoking and tobacco products. In
use, the user experiences a similar satisfaction and physical
sensation to those experienced from a traditional smoking or
tobacco product, and exhales an aerosol mist or vapor of similar
appearance to the smoke exhaled when using such traditional smoking
or tobacco products.
[0014] One approach for a smoking substitute device is the
so-called "vaping" approach, in which a vaporizable liquid,
typically referred to (and referred to herein) as "e-liquid", is
heated by a heater to produce an aerosol vapor which is inhaled by
a user. The e-liquid typically includes a base liquid as well as
nicotine and/or flavorings. The resulting vapor therefore also
typically contains nicotine and/or flavorings. The base liquid may
include propylene glycol and/or vegetable glycerin.
[0015] A typical vaping smoking substitute device includes a
mouthpiece, a power source (typically a battery), a tank for
containing e-liquid, as well as a heater. In use, electrical energy
is supplied from the power source to the heater, which heats the
e-liquid to produce an aerosol (or "vapor") which is inhaled by a
user through the mouthpiece.
[0016] Vaping smoking substitute devices can be configured in a
variety of ways. For example, there are "closed system" vaping
smoking substitute devices, which typically have a sealed tank and
heating element. The tank is pre-filled with e liquid and is not
intended to be refilled by an end user. One subset of closed system
vaping smoking substitute devices includes a main body which
includes the power source, wherein the main body is configured to
be physically and electrically coupled to a consumable including
the tank and the heater. The consumable may also be referred to as
a cartomizer. In this way, when the tank of a consumable has been
emptied, that consumable is disposed of. The main body can be
reused by connecting it to a new, replacement, consumable. Another
subset of closed system vaping smoking substitute devices is
completely disposable, and intended for one-use only.
[0017] There are also "open system" vaping smoking substitute
devices which typically have a tank that is configured to be
refilled by a user. In this way the device can be used multiple
times.
[0018] An example vaping smoking substitute device is the Myblu.TM.
e-cigarette. The Myblu.TM. e cigarette is a closed system device
which includes a main body and a consumable. The main body and
consumable are physically and electrically coupled together by
pushing the consumable into the main body. The main body includes a
rechargeable battery. The consumable includes a mouthpiece, a
sealed tank which contains e-liquid (also referred to as an aerosol
precursor), as well as a heater, which for this device is a heating
filament coiled around a portion of a wick. The wick is partially
immersed in the e-liquid, and conveys e-liquid from the tank to the
heating filament. The device is activated when a microprocessor on
board the main body detects a user inhaling through the mouthpiece.
When the device is activated, electrical energy is supplied from
the power source to the heater, which heats e-liquid from the tank
to produce a vapor which is inhaled by a user through the
mouthpiece.
[0019] For a smoking substitute device, it is desirable to deliver
nicotine into the user's lungs, where it can be absorbed into the
bloodstream. As explained above, in the so-called "vaping"
approach, "e-liquid" is heated by a heating device to produce an
aerosol vapor which is inhaled by a user. Many e-cigarettes also
deliver flavor to the user, to enhance the experience. Flavor
compounds are contained in the e-liquid that is heated. Heating of
the flavor compounds may be undesirable as the flavor compounds are
inhaled into the user's lungs. Toxicology restrictions are placed
on the amount of flavor that can be contained in the e-liquid. This
can result in some e-liquid flavors delivering a weak and
underwhelming taste sensation to consumers in the pursuit of
safety.
[0020] In aerosol delivery devices, it is desirable to avoid large
liquid droplets reaching a user's mouth.
[0021] The present disclosure has been devised in light of the
above considerations.
SUMMARY OF THE DISCLOSURE
[0022] First Mode: An Aerosol-Generation Apparatus, Comprising a
Fluid-Transfer Article Having an Activation Surface and Configured
for Thermal Interaction with a Heating Surface
[0023] At its most general, a first mode of the present disclosure
proposes that an aerosol-generation apparatus is provided, which
has a heater and a fluid-transfer article, with the fluid-transfer
article having an activation surface at an end of the article and
being configured for thermal interaction with a heating surface of
the heater. The activation surface has at least one channel
therein, which channel opposes the heating surface and is open
towards the heating surface. The heater has a substrate and at
least one heating element on a part of the substrate. The
fluid-transfer article is positioned so that the or each channel
faces a part of the substrate other than the part of the substrate
of which the or each heating element is formed.
[0024] Thus, the or each heating element is not aligned with the or
each channel. Instead, it is aligned with a part of the activation
surface other than that the or each channel, so that the or each
heating element is aligned with the part or parts of the activation
surface which project towards the heater.
[0025] Thus, the present disclosure may provide an
aerosol-generation apparatus comprising a heater and a
fluid-transfer article, said fluid-transfer article having a first
region for holding an aerosol precursor and for transferring said
aerosol precursor to an activation surface of a second region of
said article, said activation surface being disposed and configured
for thermal interaction with a heating surface of said heater; said
second region comprising at least one discontinuity in said
activation surface to form a corresponding at least one channel
between said second region and said heating surface and being
configured such that, when the fluid transfer article is arranged
with respect to said heating surface of the heater for thermal
interaction therebetween, the or each said arcuate surface portion
opposes said heating surface, opens towards said heating surface
and provides an air-flow pathway across said heating surface
wherein the heater comprises a substrate defining said heating
surface, and at least one heating element formed on a part of said
heating surface, and said at least one channel opposes a further
part of said heating surface other than said part of said heating
surface on which said heating element is formed.
[0026] The activation surface may be disposed at an end of the
fluid-transfer article. Optionally, said activation surface is
configured such that, when the fluid transfer article is arranged
with respect to a said heating surface for thermal interaction
therebetween, the or each said discontinuity is spaced apart from
said heating surface.
[0027] Advantageously, the or each said channel is at least partly
defined by a pair of spaced apart side walls, and an arcuate
surface portion extending between said wall portions to form a
ceiling portion of said channel.
[0028] Optionally, said arcuate surface portion blends smoothly
with each of said side walls, thereby eliminating a sharp corner
therebetween.
[0029] Alternatively, the or each channel may be at least partially
defined by a pair of spaced apart side walls and a flat surface
portion, said flat surface portion extending between said wall
portions to form a ceiling portion of said channel. A further
possibility is that the or each channel is at least partially
defined by a pair of side walls, said side walls being inclined
relative to each other to meet an apex portion of said channel.
[0030] Conveniently, said side walls are substantially planar.
[0031] Conveniently, at least said second region is formed from a
polymeric wicking material.
[0032] Advantageously, said first and second regions are both
formed from said polymeric wicking material.
[0033] Optionally, said polymeric wicking material is porous.
[0034] Conveniently, said polymeric wicking material is configured
such that pore diameter in said first region is greater than pore
diameter in said second region.
[0035] Advantageously, said polymeric wicking material is heat
resistant.
[0036] Optionally, said polymeric wicking material is a hydrophilic
material that is configured to transfer fluid from said first
region to said second region.
[0037] Conveniently, said polymeric wicking material is of greater
hydrophilicity in said second region than said first region.
[0038] According to another aspect of the first mode of the present
disclosure, there may be provided an aerosol delivery system
comprising an aerosol-generation apparatus as discussed above, and
a carrier, which carrier has a housing containing the heater and
the fluid-transfer article.
[0039] Preferably, the housing has an inlet and an outlet, with the
air-flow pathway extending between the inlet and outlet.
[0040] The disclosure includes the combination of the aspects and
preferred features of the first mode described except where such a
combination is clearly impermissible or expressly avoided.
[0041] The skilled person will appreciate that except where
mutually exclusive, a feature or parameter described in relation to
any one of the above aspects of the first mode may be applied to
any other aspect of the first mode. Furthermore, except where
mutually exclusive, any feature or parameter of the first mode
described herein may be applied to any aspect and/or combined with
any other feature or parameter of the first mode described
herein.
[0042] Second Mode: An Aerosol-Generation Apparatus has a
Fluid-Transfer Article which Holds and Transfers Aerosol Precursor
to an Activation Surface
[0043] At its most general, a second mode of the present disclosure
proposes that an aerosol-generation apparatus has a fluid-transfer
article which holds aerosol precursor and which transfers that
aerosol precursor to an activation surface. That activation surface
is proximate but spaced from a heater of the aerosol-generation
apparatus, so that an air-flow pathway is defined between the
activation surface and the heater. At least that part of the
fluid-transfer article forming the activation surface is made from
a porous polymer material. Thus, unlike arrangements in which the
heater is brought in to direct contact with the activation surface,
the present disclosure has a space therebetween such that the
activation surface and the heater do not make contact with one
another. The present disclosure also uses porous polymer material
to form the part of the fluid-transfer article forming the
activation surface. It is part which has a wicking action.
[0044] Thus, according to the present disclosure, there may be
provided an aerosol-generation apparatus comprising a heater and a
fluid-transfer article, the fluid-transfer article comprising a
first region for holding an aerosol precursor and for transferring
said aerosol precursor to an activation surface of a second region
of said fluid-transfer article, said second region being formed
from a porous polymer material, said activation surface facing said
heater with a space therebetween so as to interact thermally with
said heater, said space defining an air-flow pathway between said
activation surface said heater.
[0045] Said activation surface may be proximate but spaced from
said heater.
[0046] Optionally, said activation surface may be disposed at an
end of said fluid-transfer article.
[0047] Optionally, said activation surface and said heater are
substantially equi-spaced apart across their entire extent. Said
activation surface and said heater may comprise complimentary
profiles.
[0048] The porous polymer material may comprise Polyetherimide
(PEI) and/or Polyether ether ketone (PEEK) and/or
Polytetrafluoroethylene (PTFE) and/or Polyimide (PI) and/or
Polyethersulphone (PES) and/or Ultra-High Molecular Weight
Polyethylene (UHMWPE) and/or Polypropylene (PP) and/or Polyethylene
Terephthalate (PET). The aerosol-generation apparatus may form part
of an aerosol delivery system which has a carrier and include a
housing containing the heater and the fluid-transfer apparatus. The
housing may have an inlet and outlet, with the air-flow pathway
extending to the inlet and outlet.
[0049] The disclosure includes the combination of the aspects and
preferred features of the second mode described except where such a
combination is clearly impermissible or expressly avoided.
[0050] Third Mode: An Aerosol Generation Apparatus has a
Fluid-Transfer Article with a First Region which Holds an Aerosol
Precursor
[0051] At its most general, a third mode of the present disclosure
proposes that an aerosol generation apparatus has a fluid-transfer
article with a first region which holds an aerosol precursor, the
first region being arranged to transfer the aerosol precursor to a
second region of the fluid-transfer article. That second region has
two parts of different materials, one part being adjacent to the
first region and the second part being of a material resistant to
higher temperatures than the material of the first part. The first
part has a plurality of holes therein and the second part extends
across those holes so that aerosol precursor in the holes will pass
to the second part of the second region. The second part is porous
for passage therethrough of the aerosol precursor from the holes to
an activation surface.
[0052] The aerosol-generation apparatus also has a heater, which
heater is positioned relative to the activation surface so as to
interact thermally therewith. In particular, the heater may be
mounted proximate but spaced from the activation surface. An
air-flow pathway may thus be defined between the heater and the
activation surface. The heater and the fluid-transfer article (and
specifically the activation surface of the fluid-transfer article)
are separable.
[0053] The separability of the fluid-transfer article and the
heater means that it is possible to replace the fluid-transfer
article without having to replace the heater. Since the aerosol
precursor will be consumed when the apparatus is used by a user, it
will normally be necessary to replace or at least refill the
fluid-transfer article periodically, as it acts as a reservoir for
the aerosol precursor.
[0054] The two different materials of the second region of the
fluid-transfer article allow one (the material of the second part)
to be adapted to the heater, whilst the other (the material of the
first part) may be a lower cost material.
[0055] As mentioned above the first part of the second region has a
plurality of holes therein. Those holes do not act as capillaries,
but instead may be of a size or sizes so that they cooperate with
the second part of the second region to define non-capillary spaces
in the second region in to which the aerosol precursor is able to
flow. Thus, the aerosol precursor may pass from the first region in
a non-capillary manner into the holes, and impinge on the second
part of the second region. It may then pass through the second part
due to the porous nature of the second part.
[0056] The second region of the fluid-transfer article may thus act
as a wick, to cause aerosol precursor to move from the first region
to the activation surface where it may be heated by the heater. The
wick may have a two-layer structure, formed by the two parts of the
second region. One of those parts is preferably being made of an
inexpensive material through which the holes pass, and the second
part is of a more heat resistant material, which will interact with
the heater at the activation surface. Aerosol precursor will be
drawn through the second region, partly because the holes will fill
with aerosol precursor, and partly because of the porous nature of
the second part of the second region.
[0057] Thus, according to the third mode of the present disclosure,
there may be provided an aerosol-generation apparatus comprising a
heater, and a fluid-transfer article, said fluid-transfer article
comprising a first region for holding an aerosol precursor and for
transferring said aerosol precursor to a second region of said
fluid-transfer article, said second region comprising a first part
of a first material, said first part being adjacent said first
region and having a plurality of holes therein, and a second part
of a second material different from the first material and being
resistant to higher temperatures than said first material, said
second part being adjacent to said first part and extending across
said plurality of holes in said first part; wherein said plurality
of holes are sized so that they cooperate with said second part of
said second region to define non-capillary spaces in said second
region into which said aerosol precursor is able to flow from said
first region in a non-capillary manner, thereby to impinge on said
second part; wherein said second part of said second region is
porous for passage therethrough of said aerosol precursor from said
plurality of holes to an activation surface of said second region,
said activation surface being disposed so as to interact thermally
with said heater, wherein said heater is mounted proximate but
spaced from said activation surface to define an air-flow pathway
between said heater and said activation surface, and wherein said
heater and said fluid-transfer article are separable.
[0058] Optionally, said plurality of holes are sufficiently large
so that they cooperate with said second part of said second region
to define non-capillary spaces in said second region.
[0059] The heater is preferably a coil, mesh or foil.
[0060] Preferably, the spacing between the activation surface and
the heater is between 0.5 mm and 0.05 mm.
[0061] Preferably, said first part of said second region is formed
of a solid polymer material having said plurality of holes
therein.
[0062] It is usually preferable that said second part of said
second region is formed of fibrous material. That fibrous material
may be ceramic fiber, glass fiber or carbon fiber. Alternatively,
the second part of the second region may be porous glass or porous
ceramic. Another possibility is that the second part of the second
region is of a porous polymer material. Another possibility is for
the first region of the fluid-transfer article to be a simple
reservoir filled with liquid aerosol precursor, from which
reservoir the liquid flows into the holes in the first part of the
second region of the fluid-transfer article.
[0063] Preferably, the plurality of holes are molded holes. As
mentioned above, it is desirable that the first part of the second
region is formed of solid polymer material and it is convenient to
mold the holes at the same time that the first part itself is
molded.
[0064] The fluid-transfer article may act as a reservoir for
aerosol precursor. One option is for the first region of said
fluid-transfer article to be of porous polymer material.
[0065] The porous polymer material of the first region may comprise
Polyetherimide (PEI) and/or Polyether ether ketone (PEEK) and/or
Polytetrafluoroethylene (PTFE) and/or Polyimide (PI) and/or
Polyethersulphone (PES) and/or Ultra-High Molecular Weight
Polyethylene (UHMWPE) and/or Polypropylene (PP) and/or Polyethylene
Terephthalate (PET). Similar materials may be used for the second
part of the second region when that second region is made of a
porous polymer material, as mentioned above.
[0066] Alternatively, the first region of the fluid-transfer
article may be a tank defining a hollow reservoir which is filled
with aerosol precursor when the apparatus is to be used.
[0067] The aerosol-generation apparatus may form part of an aerosol
delivery system which has a carrier which includes a housing
containing the fluid-transfer article. The aerosol delivery system
may then include a further housing supporting the heater. The
housing and the further housing may be mutually separable, to allow
the carrier to be removed from the rest of the aerosol delivery
system.
[0068] The further housing may have an inlet with the air-flow
pathway extending to the inlet.
[0069] According to another aspect of the third mode of the present
disclosure, there is provided an aerosol-generation apparatus
comprising a heater, and a fluid-transfer article, said
fluid-transfer article comprising a first region for holding an
aerosol precursor and for transferring said aerosol precursor to a
second region of said fluid-transfer article, said second region
comprising a first part of a first material, said first part being
adjacent said first region and having a plurality of holes therein,
and a second part of a second material different from the first
material and being resistant to higher temperatures than said first
material, said second part being adjacent to said first part and
extending across said plurality of holes in said first part;
wherein said second part of said second region is porous for
passage therethrough of said aerosol precursor from said plurality
of holes to an activation surface of said second region, said
activation surface being disposed so as to interact thermally with
said heater; wherein said plurality of holes are sufficiently large
so that they cooperate with said second part of said second region
to define non-capillary spaces in said second region into which
said aerosol precursor is able to flow from said first region in a
non-capillary manner, thereby to impinge on said second part, and
wherein said heater is mounted proximate but spaced from said
activation surface to define an air-flow pathway between said
heater and said activation surface, and wherein said heater and
said fluid-transfer article are separable.
[0070] The disclosure includes the combination of the aspects and
preferred features of the third mode described except where such a
combination is clearly impermissible or expressly avoided.
[0071] Fourth Mode: An Aerosol Generation Apparatus has a
Fluid-Transfer Article which Holds Aerosol Precursor and which
Transfers that Aerosol Precursor to a Transfer Surface
[0072] At its most general, a fourth mode of the present disclosure
proposes that an aerosol generation apparatus has a fluid-transfer
article which holds aerosol precursor and which transfers that
aerosol precursor to a transfer surface. The fluid-transfer article
is mounted adjacent (e.g., in contact with) a heater, so that the
transfer surface is the closest part of the fluid-transfer article
to the heater. The heater has a porous element, which allows
aerosol precursor to pass from the transfer surface into the
heater. The porous element has an activation surface on the
opposite side of the porous element from the fluid-transfer
article, on which activation surface is mounted at least one
heating element for heating aerosol precursor which has reached the
activation surface.
[0073] The separability of the fluid-transfer article and the
heater means that the fluid-transfer article can be replaced
without having to replace the heater. Since the aerosol precursor
will be consumed when the apparatus is used by a user, it may be
necessary to replace the fluid-transfer article, which acts as a
reservoir for the aerosol precursor. The heater may remain and need
not be replaced when the aerosol precursor is consumed.
[0074] The heater element or elements are normally mounted directly
on the activation surface of the porous element of the heater. In
such an arrangement, there will normally be an air-flow pathway
adjacent the activation surface of the heater, so that vapor or
aerosol/vapor mixture released from the activation surface by the
heating effect of the heating element or elements may mix with the
air-flow and pass to the user.
[0075] In such an arrangement, the air flow may have the effect of
pulling liquid through the porous element from the fluid-transfer
article onto the activation surface of the heater. This effect is
assisted by the heating of the aerosol precursor by the heating
element or elements, which causes the aerosol precursor to be
liberated from the porous element as vapor or a vapor/aerosol
mixture, thereby creating a flow of aerosol precursor through the
porous heater.
[0076] Thus, according to the fourth mode of the present
disclosure, there may be provided an aerosol-generation apparatus
comprising a heater and a fluid-transfer article, said
fluid-transfer article comprising a first region for holding an
aerosol precursor and for transferring said aerosol precursor to a
transfer surface of said fluid-transfer article, the heater
comprising a porous element adjacent to but separable from said
transfer surface of said fluid-transfer article and at least one
heating element on an activation surface of said porous element,
which activation surface is on the opposite side of the porous
element from the fluid-transfer article.
[0077] Preferably, said heating element or elements are mounted on
said activation surface. The heating element or elements are then
preferably coil, mesh or foil. There may be an air-flow pathway
adjacent the activation surface.
[0078] The transfer surface of the fluid-transfer article may be
planar, with the heater having a matching planar surface adjacent
thereto. Thus, it is straightforward for aerosol precursor to pass
from the transfer surface to the heater. Alternatively, the
transfer surface and the adjacent surface of the heater may be
convoluted, with a convolution to the transfer surface and the
convolutions of the heater surface matching to provide mutual
engagement. For example, the heater may have upwardly protruding
triangular or conical projections that fit inside corresponding
triangular or conical recesses in the transfer surface. Castellated
and sinusoidal arrangements are also possible. Such convoluted
arrangements have the advantage that they increase the surface area
for liquid transfer between the transfer surface and the heater,
although they require more manufacturing to achieve good mutual
engagement.
[0079] The fluid-transfer article may act as a reservoir for
aerosol precursor. Preferably, said first region of fluid-transfer
article is of porous polymer material. The porous element of the
heater may also be formed from porous polymer material.
Alternatively, the porous element of the heater may be of fibrous
material, such as ceramic fiber, glass fiber or carbon fiber, or
from porous glass or porous ceramic.
[0080] The porous polymer material may comprise Polyetherimide
(PEI) and/or Polyether ether ketone (PEEK) and/or
Polytetrafluoroethylene (PTFE) and/or Polyimide (PI) and/or
Polyethersulphone (PES) and/or Ultra-High Molecular Weight
Polyethylene (UHMWPE) and/or Polypropylene (PP) and/or Polyethylene
Terephthalate (PET).
[0081] The aerosol-generation apparatus may form part of an aerosol
delivery system which has a carrier which includes a housing
containing the fluid-transfer apparatus. There may then be a
further housing containing the heater, with the housing and the
further housing being separable. The further housing may have an
inlet and outlet, with the air-flow pathway extending to the inlet
and outlet.
[0082] The further housing may have a plate which is spaced from
the activation of the porous structure of the heater, with the
air-flow pathway passing between the activation surface and the
plate.
[0083] The plate may have a plurality of recesses in its surface
facing the activation surface, with the air-flow pathway passing
through the recesses.
[0084] The disclosure includes the combination of the aspects and
preferred features of the fourth mode described except where such a
combination is clearly impermissible or expressly avoided.
[0085] Fifth Mode: A Fluid Transfer Article Comprising a First
Region Having an Aerosol Precursor and for Transferring Said
Aerosol Precursor to an Activation Surface of a Second Region of
Said Article
[0086] In a first aspect of a fifth mode the present disclosure
there is provided a fluid transfer article comprising a first
region having an aerosol precursor and for transferring said
aerosol precursor to an activation surface of a second region of
said article, said activation surface being disposed at an end of
said article configured for thermal interaction with a heater of an
aerosol-generation apparatus, and the aerosol precursor having a
first dynamic viscosity in an unheated state and a lower second
dynamic viscosity in a heated state, wherein in the unheated state
the aerosol precursor is substantially retained in the fluid
transfer article, both at atmospheric pressure and when a pressure
below atmospheric pressure is applied; and in the heated state the
aerosol precursor is substantially drawn from the activation
surface of said article when a pressure below atmospheric pressure
is applied. Advantageously, this combination of features provides a
fluid transfer article that does not substantially leak excess
aerosol precursor when heated by a heating element.
[0087] Preferably, in the heated state, the aerosol precursor at
the activation surface is at about 25.degree. C., such as
20.degree. C. or 30.degree. C.
[0088] Preferably, in the heated state, the aerosol precursor is
substantially retained in said article at atmospheric pressure.
Advantageously, the fluid aerosol precursor and transfer article
are so configured as to prevent passive leaking of the aerosol
precursor when the fluid transfer article is in use.
[0089] Preferably, the aerosol precursor has a first dynamic
viscosity in the unheated state of from 0.05 to 1.5 Pa-s.
Advantageously, this viscosity profile provides good retention of
the aerosol precursor in the fluid transfer article under ambient
conditions.
[0090] Preferably, the aerosol precursor has a second dynamic
viscosity, in a heated state, of from 0.01 to less than 0.05 Pa-s.
Advantageously, this viscosity profile allows flow of the aerosol
precursor from the fluid transfer article under heated
conditions.
[0091] Preferably, the temperature difference between the unheated
state and the heated state is 10.degree. C. or more. Preferably,
the temperature difference is 25.degree. C. or more, such as
50.degree. C. or more or 100.degree. C. or more. Advantageously,
this reduces the heat and/or time required to manipulate the
aerosol precursor between the ambient retention state and the
heated mobile state.
[0092] Preferably, the temperature at the activation surface in the
heated state is 35 or more, such as 50.degree. C., 75.degree. C. or
100.degree. C. or more. Advantageously, this reduces the heat
and/or time required to manipulate the aerosol precursor between
the ambient retention state and the heated mobile state.
[0093] Preferably, the pressure below atmospheric pressure is 0.7
atm to <1 atm. Advantageously, this lower external pressure
draws aerosol precursor at the second dynamic viscosity from the
fluid transfer article.
[0094] Preferably, 99% or more of the aerosol precursor is retained
by the fluid transfer article when kept in the unheated state at 1
atm for 30 days. Advantageously, the fluid transfer article shows
excellent retention of the aerosol precursor at ambient pressure
and temperature.
[0095] Preferably, a fluid transfer article according to any one of
the preceding claims wherein 99% or more of the aerosol precursor
is retained by the fluid transfer article when kept in the unheated
state at 0.8 atm for 24 hours. Advantageously, the fluid transfer
article shows excellent retention of the aerosol precursor under a
mild vacuum at ambient temperature.
[0096] Preferably, the first and second regions are porous.
Advantageously, this contributes to improved control of the aerosol
precursor within the fluid transfer article.
[0097] Preferably, the first and second regions each have a mean
pore diameter of 250 .mu.m or less, preferably 200 .mu.m or less,
more preferably 150 .mu.m or less, more preferably 100 .mu.m or
less, more preferably 1 to 90 .mu.m, more preferably 2 to 80 .mu.m,
more preferably 5 to 70 .mu.m, more preferably 10 to 50 .mu.m, more
preferably 20 to 40 .mu.m, more preferably 25 to 35 .mu.m, more
preferably 28 to 32 .mu.m. Advantageously, such pore sizes
contribute to improved control of the aerosol precursor within the
fluid transfer article.
[0098] Preferably, the pore diameter in the first region is greater
than the pore diameter in the second region. Advantageously, this
allows increased amounts of aerosol precursor in the first region
while the second region exposed towards the heater controls
delivery of the aerosol precursor out of the fluid transfer
article.
[0099] Optionally, the first and second regions, in accordance with
various aspects of the fifth mode of the present disclosure, have
pores with substantially the same spherical geometry and the pore
size is the diameter of the largest cross-section for any
particular pore space. For example, known porous materials applied
in this field typically do not vary by more than about 15% from a
mean size.
[0100] Determining average pore size can be done using various
measuring instruments which are capable of accurately measuring
pore size. For example, one instrument used to measure pore size
and pore volume is the Mercury Intrusion Porosimeter.
[0101] Preferably, the first region is enclosed by the second
region. Advantageously, this controls the delivery of the aerosol
out of the fluid transfer article in all directions, for instance,
when it is freestanding and not incorporated in any other
device.
[0102] Preferably, the first region has a void volume ratio of 25
to 60%, preferably 26 to 50%, more preferably 27 to 40%, more
preferably 28 to 35% more preferably 29 to 30%. Advantageously,
this contributes to improved control of the aerosol precursor
within the fluid transfer article.
[0103] Advantageously, pore diameters and/or void volume ratios are
selected to obtain effective control of delivery of the aerosol to
the air, maintain structural integrity of the relevant regions and
prevent clogging.
[0104] Advantageously, larger pore sizes and/or high void volumes
provide more storage capacity an excellent precursor aerosol
transport kinetics. However, too large pore sizes or void volumes
cause leaking upon inversion of the reservoir and also have less
capacity for capillary transport of the liquid from the
reservoir.
[0105] Advantageously, smaller pore sizes and/or low void volumes
are more resistant to leakage and provide excellent structural
integrity. However, too small pore sizes or void volumes result in
poor aerosol precursor transport kinetics.
[0106] Advantageously, the first and second regions together have
excellent wicking properties such that, when in use, the heating
element of an aerosol-generation apparatus forms a temperature
gradient throughout the fluid transfer article having a lower
temperature distal to the heating element, such that the viscosity
of aerosol precursor not proximal to the heating element is also
lowered (at a temperature between the heated and unheated state)
and is drawable towards the heating element to replace the aerosol
precursor at the activation surface, adjacent to the heating
element.
[0107] Preferably, the aerosol precursor comprises one or more
solvents selected from water, propylene glycol, 1,3-butanediol,
1,3-propanediol, ethylene glycol, diethylene glycol and vegetable
glycerin. Advantageously, this contributes to improved control of
the aerosol precursor within the fluid transfer article.
[0108] Preferably, the aerosol precursor comprises 60 to 80%
vegetable glycerin and 20 to 40% propylene glycol. Advantageously,
vegetable glycerin forms a vapor that gives the impression of
cigarette smoke. Vegetable glycerin also has a relatively higher
dynamic viscosity that can contribute to retention of the aerosol
precursor in the fluid transfer article in the unheated state.
[0109] Preferably, the aerosol precursor comprises 20 to 40%
vegetable glycerin and 60 to 80% propylene glycol. Advantageously,
propylene glycol vaporizes at a lower temperature than vegetable
glycerin. Furthermore, an aerosol precursor having more propylene
glycol than vegetable glycerin has a higher wicking rate, capillary
efficiency, evaporates easier and provides less vapor. Propylene
glycol also has a relatively lower dynamic viscosity that can
contribute to mobility of the aerosol precursor in the heated
state.
[0110] Preferably, the fluid transfer article is provided with a
carrier comprising a housing containing said fluid-transfer
article.
[0111] Preferably, there is an aerosol generation apparatus
comprising the fluid transfer article of the first aspect of the
fifth mode of the disclosure, the aerosol generation apparatus
comprising a heater wherein said heater contacts the activation
surface of the fluid transfer article so as to interact thermally
with said activation surface; and wherein said heater and said
activation surface are separable.
[0112] Preferably, there is provided a smoking substitute device
comprising a fluid transfer article according to the first aspect
of the fifth mode of the disclosure.
[0113] In a second aspect of the fifth mode, there is provided use
of a fluid transfer article according to the first aspect of the
fifth mode of the disclosure in a substitute smoking device.
[0114] Optionally, the aerosol generation apparatus has a
fluid-transfer article according to the first aspect of the fifth
mode of the disclosure. Optionally, the second region of the
aerosol generation apparatus has two parts of different materials,
one part being adjacent to the first region and the second part
being of a material resistant to higher temperatures than the
material of the first part. The first part has a plurality of holes
therein and the second part extends across those holes so that
aerosol precursor in the holes will pass to the second part of the
second region. The second part is porous for passage therethrough
of the aerosol precursor from the holes to an activation
surface.
[0115] The aerosol-generation apparatus also has a heater, which
heater contacts the activation surface so as to interact thermally
therewith. The heater is not bonded to the activation surface,
instead it may make abutting unbonded contact so that the heater
and the activation surface are separable.
[0116] The separability of the fluid-transfer article and the
heater means that it is possible to replace the fluid-transfer
article without having to replace the heater. Since the aerosol
precursor will be consumed when the apparatus is used by a user, it
will normally be necessary to replace or at least refill the
fluid-transfer article periodically, as it acts as a reservoir for
the aerosol precursor.
[0117] The two different materials of the second region of the
fluid-transfer article allow one (the material of the second part)
to be adapted to the heater, whilst the other (the material of the
first part) may be a lower cost material.
[0118] As mentioned above the first part of the second region has a
plurality of holes therein. Those holes do not act as capillaries,
but instead may be of a size or sizes so that they cooperate with
the second part of the second region to define non-capillary spaces
in the second region in to which the aerosol precursor is able to
flow. Thus, the aerosol precursor may pass from the first region in
a non-capillary manner into the holes, and impinge on the second
part of the second region. It may then pass through the second part
due to the porous nature of the second part.
[0119] The heater is mounted in contact with the activation surface
of the second region. In such an arrangement, there will normally
be an air-flow pathway adjacent at least part of the activation
surface, so that vapor or aerosol/vapor mixture released from the
activation surface by the heating effect of the heater may mix with
the air-flow and pass to the user. Furthermore, in such an
arrangement, the air-flow pathway will normally pass on the
opposite side of the heater from the activation surface.
[0120] The second region of the fluid-transfer article may thus act
as a wick, to cause aerosol precursor to move from the first region
to the activation surface where it may be heated by the heater. The
wick may have a two-layer structure, formed by the two parts of the
second region. One of those parts is preferably being made of an
inexpensive material through which the holes pass, and the second
part is of a more heat resistant material, which will interact with
the heater at the activation surface. Aerosol precursor will be
drawn through the second region, partly because the holes will fill
with aerosol precursor, and partly because of the porous nature of
the second part of the second region.
[0121] Optionally, there may be provided an aerosol-generation
apparatus comprising a heater and a fluid-transfer article
according to the first aspect of the fifth mode of the disclosure,
said second region of the fluid-transfer article comprising a first
part of a first material, said first part being adjacent said first
region and having a plurality of holes therein, and a second part
of a second material different from the first material and being
resistant to higher temperatures than said first material, said
second part being adjacent to said first part and extending across
said plurality of holes in said first part; wherein said plurality
of holes are sized so that they cooperate with said second part of
define non-capillary spaces in said second region into which said
aerosol precursor is able to flow from said first region in a
non-capillary manner thereby to impinge on said second part;
wherein said second part of said second region is porous for
passage therethrough of said aerosol precursor from said plurality
of holes to an activation surface of said second region; wherein
said heater contacts said activation surface so as to interact
thermally with said activation surface; and wherein said heater and
said activation surface are separable.
[0122] The heater is preferably a coil, mesh or foil. There may
then be an air-flow pathway adjacent at least a part of the
activation surface. Since the heater is in contact with the
activation surface, a part of said air-flow pathway may be on the
opposite of the heater from the activation surface.
[0123] Preferably, said first part of said second region is formed
of a solid polymer material having said plurality of holes
therein.
[0124] It is usually preferable that said second part of said
second region is formed of fibrous material. That fibrous material
may be ceramic fiber, glass fiber or carbon fiber. Alternatively,
the second part of the second region may be porous glass or porous
ceramic. Another possibility is that the second part of the second
region is of a porous polymer material. Another possibility is for
the first region of the fluid-transfer article to be a simple
reservoir filled with liquid aerosol precursor, from which
reservoir the liquid flows into the holes in the first part of the
second region of the fluid-transfer article.
[0125] Preferably, the plurality of holes are molded holes. As
mentioned above, it is desirable that the first part of the second
region is formed of solid polymer material and it is convenient to
mold the holes at the same time that the first part itself is
molded.
[0126] The fluid-transfer article may act as a reservoir for
aerosol precursor. One option is for the first region of said
fluid-transfer article to be of porous polymer material.
[0127] The porous polymer material of the first region may comprise
Polyetherimide (PEI) and/or Polyether ether ketone (PEEK) and/or
Polytetrafluoroethylene (PTFE) and/or Polyimide (PI) and/or
Polyethersulphone (PES) and/or Ultra-High Molecular Weight
Polyethylene (UHMWPE) and/or Polypropylene (PP) and/or Polyethylene
Terephthalate (PET). Similar materials may be used for the second
part of the second region when that second region is made of a
porous polymer material, as mentioned above.
[0128] Alternatively, the first region of the fluid-transfer
article may be a simple hollow reservoir which is filled with
aerosol precursor when the apparatus is to be used.
[0129] The aerosol-generation apparatus may form part of an aerosol
delivery system which has a carrier which includes a housing
containing the fluid-transfer article. The aerosol delivery system
may then include a further housing supporting the heater. The
housing and the further housing may be mutually separable, to allow
the carrier to be removed from the rest of the aerosol delivery
system.
[0130] The further housing may have an inlet with the air-flow
pathway extending to the inlet. It may also have a plate mounted in
the further housing at a position spaced from the heater so that
the air-flow pathway passes between the activation surface and the
plate. The plate may optionally have a plurality of recesses in its
surface facing the activation surface with the air-flow pathway
passing through said recesses.
[0131] The disclosure includes the combination of the aspects and
preferred features of the fifth mode described except where such a
combination is clearly impermissible or expressly avoided.
[0132] Sixth Mode: An Aerosol Generation Apparatus has a
Fluid-Transfer Article with a First Region which Holds an Aerosol
Precursor
[0133] At its most general, a sixth mode of the present disclosure
proposes that an aerosol generation apparatus has a fluid-transfer
article with a first region which holds an aerosol precursor, the
first region being arranged to transfer the aerosol precursor to a
second region of the fluid-transfer article. That second region has
two parts of different materials, one part being adjacent to the
first region and the second part being of a material resistant to
higher temperatures than the material of the first part. The first
part has a plurality of holes therein and the second part extends
across those holes so that aerosol precursor in the holes will pass
to the second part of the second region. The second part is porous
for passage therethrough of the aerosol precursor from the holes to
an activation surface.
[0134] The second part of the second region has one or more
recesses therein opening towards the heater and forming one or more
gaps between the activation surface and the heater. The one or more
gaps then form at least one air-flow pathway along the activation
surface. The gaps may thus form channels in the second part of the
second region at the activation surface, along which air may
flow.
[0135] The aerosol-generation apparatus also has a heater, which
heater preferably contacts a part of the activation surface so as
to interact thermally therewith. The heater is not bonded to the
activation surface, instead it may make abutting unbonded contact
so that the heater and the activation surface are separable.
Alternatively, the heater may be spaced from the activation
surface.
[0136] The separability of the fluid-transfer article and the
heater means that it is possible to replace the fluid-transfer
article without having to replace the heater. Since the aerosol
precursor will be consumed when the apparatus is used by a user, it
will normally be necessary to replace or at least refill the
fluid-transfer article periodically, as it acts as a reservoir for
the aerosol precursor.
[0137] The two different materials of the second region of the
fluid-transfer article allow one (the material of the second part)
to be adapted to the heater, whilst the other (the material of the
first part) may be a lower cost material.
[0138] As mentioned above the first part of the second region has a
plurality of holes therein. Preferably, those holes do not act as
capillaries, but instead may be of a size or sizes so that they
cooperate with the second part of the second region to define
non-capillary spaces in the second region in to which the aerosol
precursor is able to flow. Thus, the aerosol precursor may pass
from the first region in a non-capillary manner into the holes, and
impinge on the second part of the second region. It may then pass
through the second part due to the porous nature of the second
part.
[0139] The second region of the fluid-transfer article may thus act
as a wick, to cause aerosol precursor to move from the first region
to the activation surface where it may be heated by the heater. The
wick may have a two-layer structure, formed by the two parts of the
second region. One of those parts is preferably being made of an
inexpensive material through which the holes pass, and the second
part is of a more heat resistant material, which will interact with
the heater at the activation surface. Aerosol precursor will be
drawn through the second region, partly because the holes will fill
with aerosol precursor, and partly because of the porous nature of
the second part of the second region.
[0140] Thus, according to the sixth mode of the present disclosure,
there may be provided an aerosol-generation apparatus comprising a
heater, and a fluid-transfer article, said fluid-transfer article
comprising a first region for holding an aerosol precursor and for
transferring said aerosol precursor to a second region of said
fluid-transfer article, said second region comprising a first part
of a first material, said first part being adjacent said first
region and having a plurality of holes therein, and a second part
of a second material different from the first material and being
resistant to higher temperatures than said first material, said
second part being adjacent to said first part and extending across
said plurality of holes in said first part; wherein said second
part of said second region is porous for passage therethrough of
said aerosol precursor from said plurality of holes to an
activation surface of said second region; said activation surface
being disposed to as to interact thermally with said heater, and
wherein said second part of said second region has at least one
recess therein opening towards said heater, said at least one
recess forming at least one gap between said activation surface and
said heater, said at least one gap forming at least one air-flow
pathway along said activation surface.
[0141] Preferably, said heater is mounted so as to be in contact
with at least one part of said activation surface. Then, it is
preferable that said heater and said activation surface are
separable.
[0142] In the sixth mode of the present disclosure, it is normally
desirable that said plurality of holes are sized to that they
cooperate with said second part of said second region to define
non-capillary spaces in said second region into which said aerosol
precursor is able to flow from said first region in a non-capillary
manner, thereby to impinge on said second part of said second
region.
[0143] The heater is preferably a coil, mesh or foil.
[0144] Preferably, said first part of said second region is formed
of a solid polymer material having said plurality of holes
therein.
[0145] It is usually preferable that said second part of said
second region is formed of fibrous material. That fibrous material
may be ceramic fiber, glass fiber or carbon fiber. Alternatively,
the second part of the second region may be porous glass or porous
ceramic. Another possibility is that the second part of the second
region is of a porous polymer material. Another possibility is for
the first region of the fluid-transfer article to be a simple
reservoir filled with liquid aerosol precursor, from which
reservoir the liquid flows into the holes in the first part of the
second region of the fluid-transfer article.
[0146] Preferably, the plurality of holes are molded holes. As
mentioned above, it is desirable that the first part of the second
region is formed of solid polymer material and it is then
convenient to mold the holes at the same time that the first part
itself is molded.
[0147] The fluid-transfer article may act as a reservoir for
aerosol precursor. One option is for the first region of said
fluid-transfer article to be of porous polymer material.
[0148] The porous polymer material of the first region may comprise
Polyetherimide (PEI) and/or Polyether ether ketone (PEEK) and/or
Polytetrafluoroethylene (PTFE) and/or Polyimide (PI) and/or
Polyethersulphone (PES) and/or Ultra-High Molecular Weight
Polyethylene (UHMWPE) and/or Polypropylene (PP) and/or Polyethylene
Terephthalate (PET). Similar materials may be used for the second
part of the second region when that second region is made of a
porous polymer material, as mentioned above.
[0149] Alternatively, the first region of the fluid-transfer
article may be a simple hollow reservoir which is filled with
aerosol precursor when the apparatus is to be used.
[0150] The aerosol-generation apparatus may form part of an aerosol
delivery system which has a carrier which includes a housing
containing the fluid-transfer article. The aerosol delivery system
may then include a further housing supporting the heater. The
housing and the further housing may be mutually separable, to allow
the carrier, and hence the fluid-transfer article, to be removed
from the rest of the aerosol delivery system.
[0151] The further housing may have an inlet with the air-flow
pathway extending to the inlet.
[0152] The disclosure includes the combination of the aspects and
preferred features of the sixth mode described except where such a
combination is clearly impermissible or expressly avoided.
[0153] Seventh Mode: An Aerosol-Generation Apparatus has a Heater
and a Fluid-Transfer Article for Holding an Aerosol Precursor
[0154] At its most general, a seventh mode of the present
disclosure proposes that an aerosol-generation apparatus has a
heater and a fluid-transfer article for holding an aerosol
precursor. A heating surface of the heater has at least one channel
therein which opposes the fluid-transfer article. Normally, the
fluid-transfer article will be arranged to transfer the aerosol
precursor to an activation surface, and it is that activation
surface of the fluid-transfer article which interacts with the
heating surface. The channel may thus be open towards the
activation surface.
[0155] Thus, the channel may define a spacing between part of the
heating surface and the activation surface, through which spacing
air can flow. It may thus form an air-flow pathway. Aerosol
precursor which reaches the activation surface may then be heated
by the heater, to form a vapor or a vapor/aerosol mixture. That
vapor or mixture may then mix with air in the air-flow pathway to
pass to the user.
[0156] Optionally, there may be a plurality of such channels, which
plurality of channels forms the air-flow pathway.
[0157] Thus, according to a first aspect of the seventh mode of the
present disclosure, there may be provided an aerosol-generation
apparatus comprising a heater and a fluid-transfer article, the
fluid-transfer article having a first region for holding an aerosol
precursor and for transferring said aerosol precursor to an
activation surface of a second region of said article, said
activation surface being configured for thermal interaction with a
heating surface of said heater; said heating surface including at
least one discontinuity therein forming a corresponding at least
one channel, the or each said channel being configured for
providing a fluid-flow pathway across said activation surface, said
heater being configured such that, when the fluid transfer article
is arranged with respect to said heating surface for thermal
interaction therebetween, the or each said channel opposes said
activation surface and opens towards said activation surface.
[0158] The activation surface may be disposed at an end of the
fluid-transfer article.
[0159] Optionally, said heating surface is configured such that,
when the fluid transfer article is arranged with respect to said
heating surface for thermal interaction therebetween, the or each
discontinuity is spaced apart from said activation surface.
[0160] Advantageously, the or each said channel may be at least
partly defined by a pair of spaced apart side walls and an arcuate
surface portion extending between said wall portions to form a
ceiling portion of said channel.
[0161] Optionally, said arcuate surface portion blends smoothly
with each of said side walls, thereby eliminating a sharp corner
therebetween.
[0162] Alternatively, the or each channel may be at least partially
defined by a pair of spaced apart side walls and a flat surface
portion, said flat surface portion extending between said wall
portions to form a ceiling portion of said channel. A further
possibility is that the or each channel is at least partially
defined by a pair of side walls, said side walls being inclined
relative to each other to meet an apex portion of said channel.
[0163] Conveniently, said side walls are substantially planar.
[0164] Conveniently, at least said second region is formed from a
polymeric wicking material.
[0165] Advantageously, said first and second regions are both
formed from said polymeric wicking material.
[0166] Optionally, said polymeric wicking material is porous.
[0167] Conveniently, said polymeric wicking material is configured
such that pore diameter in said first region is greater than pore
diameter in said second region.
[0168] Advantageously, said polymeric wicking material is heat
resistant.
[0169] Optionally, said polymeric wicking material is a hydrophilic
material that is configured to transfer fluid from said first
region to said second region.
[0170] Conveniently, said polymeric wicking material is of greater
hydrophilicity in said second region than said first region.
[0171] According to another aspect of the seventh mode of the
present disclosure, there may be provided an aerosol delivery
system having an aerosol-generation apparatus as discussed above
and a carrier, the carrier having a housing containing said heater
and said fluid-transfer article.
[0172] Preferably, said housing has an inlet and an outlet. The
air-flow pathway may then extend to said inlet and said outlet,
said air-flow pathway passing said arcuate surface portion of said
heating surface.
[0173] The disclosure includes the combination of the aspects and
preferred features of the seventh mode described except where such
a combination is clearly impermissible or expressly avoided.
[0174] Eighth Mode: An Aerosol-Generation Apparatus has a
Fluid-Transfer Article which Holds Aerosol Precursor and which
Transfers that Aerosol Precursor to an Activation Surface
[0175] At its most general, an eighth mode the present disclosure
proposes that an aerosol-generation apparatus has a fluid-transfer
article which holds aerosol precursor and which transfers that
aerosol precursor to an activation surface. That activation surface
is in abutting unbonded contact with a heater of the
aerosol-generation apparatus, and an air-flow pathway is defined on
the opposite side of the heater from the activation surface. The
fluid-transfer article is separable from the rest of the
aerosol-generation apparatus.
[0176] Thus, when the fluid-transfer article is mounted to the rest
of the aerosol-generation apparatus, the activation surface is in
contact with the heater so that it will be heated when the heater
is active. Since that contact is unbonded, the activation surface
and heater are separable and will separate from one another when
the fluid-transfer article is removed from the rest of the
aerosol-generation apparatus. Since the aerosol precursor will be
consumed as the user uses the apparatus, this will allow the
fluid-transfer article to be removed, and be replaced or refilled
with aerosol precursor, without needing to replace the heater.
[0177] Thus, according to the present disclosure, there may be
provided an aerosol-generation apparatus comprising a heater and a
separable fluid-transfer article, the fluid-transfer article
comprising a first region for holding an aerosol precursor and for
transferring said aerosol precursor to an activation surface of a
second region of said fluid-transfer article, said activation
surface being in abutting unbonded contact with said heater so as
to interact thermally with said heater, the apparatus having an
air-flow pathway on the opposite side of said heater from said
activation surface.
[0178] The activation surface is preferably planar to allow it to
make good contact with the heater. The heater is preferably a foil
or mesh heater. The heater will normally need to have at least one
gap forming an opening therein to enable heated aerosol precursor,
in the form of vapor and/or a vapor/aerosol mixture, to pass
through the heater from the activation surface to the air-flow
pathway.
[0179] The second region of the fluid-transfer article which forms
the activation surface will normally have a wicking effect, so that
aerosol precursor in the fluid-transfer article will be transported
to the activation surface. For example, second region may be formed
of a porous polymer material. Alternatively, it may be formed of a
fibrous material, such as glass or ceramic fiber material. Other
alternatives include sintered glass, ceramic or carbon, or carbon
or glass foam. The first part of the fluid-transfer article may act
as a reservoir for the aerosol precursor. That region may simply be
a tank for liquid, or may be of porous polymer material which holds
the aerosol precursor.
[0180] The aerosol-generation apparatus may form part of an aerosol
delivery system which has a carrier and which may include a housing
containing the fluid-transfer apparatus. There may then be a
further housing supporting the heater and in which a part of the
air-flow pathway is formed. Thus, the fluid-transfer article may be
separable from the rest of the apparatus by removing the carrier
therefrom.
[0181] The disclosure includes the combination of the aspects and
preferred features of the eighth mode described except where such a
combination is clearly impermissible or expressly avoided.
[0182] Ninth Mode: An Aerosol Generation Apparatus has a
Fluid-Transfer Article with a First Region which Holds an Aerosol
Precursor
[0183] At its most general, a ninth mode of the present disclosure
proposes that an aerosol generation apparatus has a fluid-transfer
article with a first region which holds an aerosol precursor, the
first region being arranged to transfer the aerosol precursor to a
second region of the fluid-transfer article. That second region has
two parts of different materials, one part being adjacent to the
first region and the second part being of a material resistant to
higher temperatures than the material of the first part. The first
part has a plurality of holes therein and the second part extends
across those holes so that aerosol precursor in the holes will pass
to the second part of the second region. The second part is porous
for passage therethrough of the aerosol precursor from the holes to
an activation surface.
[0184] The aerosol-generation apparatus also has a heater, which
heater contacts the activation surface so as to interact thermally
therewith. The heater is not bonded to the activation surface,
instead it may make abutting unbonded contact so that the heater
and the activation surface are separable.
[0185] The separability of the fluid-transfer article and the
heater means that it is possible to replace the fluid-transfer
article without having to replace the heater. Since the aerosol
precursor will be consumed when the apparatus is used by a user, it
will normally be necessary to replace or at least refill the
fluid-transfer article periodically, as it acts as a reservoir for
the aerosol precursor.
[0186] The two different materials of the second region of the
fluid-transfer article allow one (the material of the second part)
to be adapted to the heater, whilst the other (the material of the
first part) may be a lower cost material.
[0187] As mentioned above the first part of the second region has a
plurality of holes therein. Those holes do not act as capillaries,
but instead may be of a size or sizes so that they cooperate with
the second part of the second region to define non-capillary spaces
in the second region in to which the aerosol precursor is able to
flow. Thus, the aerosol precursor may pass from the first region in
a non-capillary manner into the holes, and impinge on the second
part of the second region. It may then pass through the second part
due to the porous nature of the second part.
[0188] The heater is mounted in contact with the activation surface
of the second region. In such an arrangement, there will normally
be an air-flow pathway adjacent at least part of the activation
surface, so that vapor or aerosol/vapor mixture released from the
activation surface by the heating effect of the heater may mix with
the air-flow and pass to the user. Furthermore, in such an
arrangement, the air-flow pathway will normally pass on the
opposite side of the heater from the activation surface.
[0189] The second region of the fluid-transfer article may thus act
as a wick, to cause aerosol precursor to move from the first region
to the activation surface where it may be heated by the heater. The
wick may have a two-layer structure, formed by the two parts of the
second region. One of those parts is preferably being made of an
inexpensive material through which the holes pass, and the second
part is of a more heat resistant material, which will interact with
the heater at the activation surface. Aerosol precursor will be
drawn through the second region, partly because the holes will fill
with aerosol precursor, and partly because of the porous nature of
the second part of the second region.
[0190] Thus, according to the ninth mode of the present disclosure,
there may be provided an aerosol-generation apparatus comprising a
heater and a fluid-transfer article, said fluid-transfer article
comprising a first region for holding an aerosol precursor and for
transferring said aerosol precursor to a second region of said
fluid-transfer article, said second region comprising a first part
of a first material, said first part being adjacent said first
region and having a plurality of holes therein, and a second part
of a second material different from the first material and being
resistant to higher temperatures than said first material, said
second part being adjacent to said first part and extending across
said plurality of holes in said first part; wherein said plurality
of holes are sized so that they cooperate with said second part of
define non-capillary spaces in said second region into which said
aerosol precursor is able to flow from said first region in a
non-capillary manner thereby to impinge on said second part;
wherein said second part of said second region is porous for
passage therethrough of said aerosol precursor from said plurality
of holes to an activation surface of said second region; wherein
said heater contacts said activation surface so as to interact
thermally with said activation surface; and wherein said heater and
said activation surface are separable.
[0191] The heater is preferably a coil, mesh or foil. There may
then be an air-flow pathway adjacent at least a part of the
activation surface. Since the heater is in contact with the
activation surface, a part of said air-flow pathway may be on the
opposite of the heater from the activation surface.
[0192] Preferably, said first part of said second region is formed
of a solid polymer material having said plurality of holes
therein.
[0193] It is usually preferable that said second part of said
second region is formed of fibrous material. That fibrous material
may be ceramic fiber, glass fiber or carbon fiber. Alternatively,
the second part of the second region may be porous glass or porous
ceramic. Another possibility is that the second part of the second
region is of a porous polymer material. Another possibility is for
the first region of the fluid-transfer article to be a simple
reservoir filled with liquid aerosol precursor, from which
reservoir the liquid flows into the holes in the first part of the
second region of the fluid-transfer article.
[0194] Preferably, the plurality of holes are molded holes. As
mentioned above, it is desirable that the first part of the second
region is formed of solid polymer material and it is convenient to
mold the holes at the same time that the first part itself is
molded.
[0195] The fluid-transfer article may act as a reservoir for
aerosol precursor. One option is for the first region of said
fluid-transfer article to be of porous polymer material.
[0196] The porous polymer material of the first region may comprise
Polyetherimide (PEI) and/or Polyether ether ketone (PEEK) and/or
Polytetrafluoroethylene (PTFE) and/or Polyimide (PI) and/or
Polyethersulphone (PES) and/or Ultra-High Molecular Weight
Polyethylene (UHMWPE) and/or Polypropylene (PP) and/or Polyethylene
Terephthalate (PET). Similar materials may be used for the second
part of the second region when that second region is made of a
porous polymer material, as mentioned above.
[0197] Alternatively, the first region of the fluid-transfer
article may be a simple hollow reservoir which is filled with
aerosol precursor when the apparatus is to be used.
[0198] The aerosol-generation apparatus may form part of an aerosol
delivery system which has a carrier which includes a housing
containing the fluid-transfer article. The aerosol delivery system
may then include a further housing supporting the heater. The
housing and the further housing may be mutually separable, to allow
the carrier to be removed from the rest of the aerosol delivery
system.
[0199] The further housing may have an inlet with the air-flow
pathway extending to the inlet. It may also have a plate mounted in
the further housing at a position spaced from the heater so that
the air-flow pathway passes between the activation surface and the
plate. The plate may optionally have a plurality of recesses in its
surface facing the activation surface with the air-flow pathway
passing through said recesses.
[0200] The disclosure includes the combination of the aspects and
preferred features of the ninth mode described except where such a
combination is clearly impermissible or expressly avoided.
[0201] Tenth Mode: A Dried Conductive Fluid is Used to Form at
Least One Heater Element on an Activation Surface of a
Fluid-Transfer Article
[0202] At its most general, a tenth mode of the present disclosure
proposes that dried conductive fluid is used to form at least one
heater element on an activation surface of a fluid-transfer
article. The activation surface has at least one channel which
opens outward. The fluid-transfer article may then act as a
reservoir for holding an aerosol precursor, and for transferring
that aerosol precursor to the activation surface. The aerosol
precursor can then be heated by the heater element or elements to
form vapor or a vapor/aerosol mixture which can then pass to a
user.
[0203] The heater element or elements are preferably formed on
parts of the activation surface other than the or each channel. The
element or elements may prevent or restrict aerosol precursor
leaving the fluid-transfer article from regions where they are
formed, and so the or each channel provides a region where the
aerosol precursor may leave the fluid-transfer article (e.g., as
vapor or a mixture of vapor and aerosol) in an unrestricted way.
The channel, or the channels together, may thus form an air-flow
pathway along the activation surface. The heater elements may
extend on to the side walls of the or each channel, to increase the
heat transfer.
[0204] Thus, there may be provided an aerosol-generation apparatus
comprising a heater and a fluid-transfer article, the
fluid-transfer article having a first region for holding an aerosol
precursor and for transferring said aerosol precursor to an
activation surface of a second region of said article, wherein said
second region comprises at least one discontinuity in said
activation surface to form a corresponding at least one channel in
said activation surface, the or each said channel being configured
for providing an air-flow pathway across said activation surface
and opening in a direction away from said first region, said heater
having at least one heater element formed on said activation
surface, said at least one heater element being of a dried
conductive fluid with electrical connections thereto.
[0205] Optionally, said activation surface is disposed at an end of
said article.
[0206] Preferably, wherein said at least one heater element is
formed on parts of said activation surface other than the or each
discontinuity, which forms the or each channel.
[0207] Normally, at least parts of said at least one heating
element are formed on parts of said activation surface between said
channels.
[0208] Advantageously, the or each said channel may be at least
partly defined by a pair of spaced apart side walls, and an arcuate
surface portion extending between said wall portions to form a
ceiling portion of said channel.
[0209] Optionally, said arcuate surface portion blends smoothly
with each of said side walls, thereby eliminating a sharp corner
therebetween.
[0210] Alternatively, the or each channel may be at least partially
defined by a pair of spaced apart side walls and a flat surface
portion, said flat surface portion extending between said wall
portions to form a ceiling portion of said channel. A further
possibility is that the or each channel is at least partially
defined by a pair of side walls, said side walls being inclined
relative to each other to meet an apex portion of said channel.
[0211] In such arrangements, the at least one heater element may be
formed on at least parts of said side walls, but preferably not on
any ceiling portion.
[0212] Conveniently, said side walls are substantially planar.
[0213] Conveniently, at least said second region is formed from a
polymeric wicking material.
[0214] Advantageously, said first and second regions are both
formed from said polymeric wicking material.
[0215] Optionally, said polymeric wicking material is porous.
[0216] Conveniently, said polymeric wicking material is configured
such that pore diameter in said first region is greater than pore
diameter in said second region.
[0217] Advantageously, said polymeric wicking material is heat
resistant.
[0218] Optionally, said polymeric wicking material is a hydrophilic
material that is configured to transfer fluid from said first
region to said second region.
[0219] Conveniently, said polymeric wicking material is of greater
hydrophilicity in said second region than said first region.
[0220] According to a second aspect of the tenth mode of the
present disclosure, there may be provided an aerosol-delivery
system comprising an aerosol-generation apparatus as discussed
above, and a carrier, the carrier having a housing containing the
heater and the fluid-transfer article. In such an aerosol-delivery
system, the housing may have an inlet and outlet, with the air-flow
pathway extending to the inlet and outlet.
[0221] According to a third aspect of the tenth mode of the present
disclosure, there may be provided a method of forming an
aerosol-generation device comprising: forming a fluid-transfer
article, the fluid-transfer article having a first region for
holding an aerosol precursor and for transferring said aerosol
precursor to an activation surface of a second region of said
article, wherein said second region comprises at least one
discontinuity in said activation surface to form a corresponding at
least one channel in said activation surface, the or each said
channel being configured for providing an air-flow pathway across
said activation surface and opening in a direction away from said
first region; dipping said activation surface in a conductive fluid
to coat at least a part of said activation surface with said
conductive fluid; drying said conductive fluid to form heater
elements; and making electrical connection to said dried conductive
fluid, thereby to form a heater on said fluid-transfer article.
[0222] The disclosure includes the combination of the aspects and
preferred features of the tenth mode described except where such a
combination is clearly impermissible or expressly avoided.
[0223] Eleventh Mode: A Heater of an Aerosol Delivery Device is
Supported by a Resilient Sealing Body
[0224] At its most general, an eleventh mode of the present
disclosure proposes that a heater of an aerosol delivery device is
supported by a resilient sealing body. The resilient sealing body
seals to both a first casing containing a reservoir for holding
aerosol precursor and a second casing which supports the heater.
The first and second casings are separable and the sealing of the
resilient sealing body to the first casing containing the reservoir
is also releasable when the first casing is separated from the
second casing.
[0225] The first casing may also support a wick arranged to receive
aerosol precursor from the reservoir, with an activation surface of
that wick making abutting unbonded contact with the heater so it
would interact thermally therewith when the first and second
casings are connected.
[0226] In this way, the resilient sealing body performs three
functions, supporting the heater, and sealing each of the first and
second casings. The sealing allows the first casing to be separated
from the second casing, for example when the aerosol precursor in
the reservoir with the first casing has been consumed. The heater
remains with the second casing, held thereto by the resilient
sealing body, so the heater does not need to be replaced when the
first casing is removed. Thus, the second casing may form the
casing of the main body, including the power source, in the second
casing its contents may form a consumable.
[0227] Thus, the present disclosure may provide an aerosol delivery
device comprising a first casing and a second casing separably
connected to said first casing, said first casing containing a
reservoir for holding an aerosol precursor, said first casing also
supporting a wick arranged to receive aerosol precursor from said
reservoir, said second casing supporting a heater, said heater
making abutting unbonded contact with an activation surface of said
wick so as to interact thermally with said activation surface;
wherein said heater is supported by said second casing via a
resilient sealing body, said resilient sealing body sealing to said
second casing to be held thereby, and releasably sealing to said
first casing such that the seal of said resilient sealing body is
releasable when said first casing is separated from said second
casing.
[0228] Preferably, the resilient sealing body has at least one bore
(also referred to hereinafter as a passage) therethrough for
passage of air from the interior of the second casing to the
activation surface of the wick. That bore may have a mouth adjacent
the heater and the activation surface, which mouth widens towards
the activation surface. This contributes to a good distribution of
air over the activation surface, to allow the air to mix with
vaporized aerosol precursor, released from the wick due to the
heating effect of the heater. Preferably, the resilient sealing
body has a planar heater support surface, with the heater mounted
thereon. That heater support service may have a slot therein, which
may communicate with the bore referred to previously which allows
for a passage of air through the resilient sealing body.
[0229] In addition to the bore described above, the resilient
sealing body may have at least one further bore therethrough, being
for the passage of one or more electrical leads from the heater to
the interior of the second casing, for connection to an electrical
power source. The electrical power source maybe, for example, a
battery.
[0230] It is desirable that the resilient sealing body is heat
resistant, since it must withstand the heat generated by the
heater. It may be, for example, of silicone material. The first
casing preferably has an outlet, which may form a mouthpiece for
the user, with there being a first air-flow pathway from the
activation surface to the outlet. In a similar way, the second
casing may have an inlet, with a second air-flow pathway from the
inlet to the activation surface. The second air-flow pathway may
pass through the bore (or some or all of the bores) in the
resilient sealing body. In this way, when the user draws on the
mouthpiece, air is drawn into the inlet and through the second
air-flow pathway to the activation surface, where it mixes with the
vaporized aerosol precursor, and the resulting mixture can then
pass along the first air-flow pathway to the user.
[0231] The disclosure includes the combination of the aspects and
preferred features of the eleventh mode described except where such
a combination is clearly impermissible or expressly avoided.
SUMMARY OF THE FIGURES
[0232] So that the disclosure may be more readily understood, and
so that further features thereof may be appreciated, embodiments of
the disclosure will now be described by way of example with
reference to the accompanying drawings.
[0233] FIG. 1 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiments of the first
mode of the present disclosure.
[0234] FIG. 2 is a cross-sectional side view illustration of part
of an apparatus of the system for aerosol delivery of FIG. 1.
[0235] FIG. 3 is a cross-sectional side view illustration of the
system and apparatus for aerosol delivery of FIG. 1.
[0236] FIG. 4 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiments of the first mode of the present
disclosure.
[0237] FIG. 5 is a cross-section side view of elements of an
aerosol carrier and of part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the first
mode of the present disclosure.
[0238] FIG. 6 is a cross-section side view of elements of an
aerosol carrier and of part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the first
mode of the present disclosure.
[0239] FIG. 7 is a perspective view illustration of the aerosol
carrier and of part of an apparatus of the system for aerosol
delivery according to one or more embodiments of the first mode of
the present disclosure.
[0240] FIG. 8 is a perspective view illustration of the aerosol
carrier and of part of an apparatus of the system for aerosol
delivery according to one or more embodiments of the first mode of
the present disclosure.
[0241] FIG. 9 is a perspective end view illustration of a
fluid-transfer article of the aerosol carrier according to one or
more embodiments of the first mode of the present disclosure.
[0242] FIG. 10 is a perspective end view illustration of a
fluid-transfer article of the aerosol carried according to one or
more embodiments of the first mode of the present disclosure.
[0243] FIG. 11 is a cross-section side view of an aerosol carrier
according to one or more embodiments of the first mode of the
present disclosure.
[0244] FIG. 12 is a perspective cross-section side view of the
aerosol carrier of FIG. 11.
[0245] FIG. 13 is an exploded perspective view illustration of a
kit-of-parts for assembling a system according to one or more
embodiments of the first mode of the present disclosure.
[0246] FIG. 14 is a cross-section side view of elements of an
aerosol carrier and of part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the first
mode of the present disclosure.
[0247] FIG. 15 is a perspective view of elements of an aerosol
carrier and of part of an apparatus of the system for aerosol
delivery according to one or more embodiments of the first mode of
the present disclosure.
[0248] FIG. 16 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiment of the second
mode of the present disclosure.
[0249] FIG. 17 is a cross-section side view illustration of part of
an apparatus of the system for aerosol delivery of FIG. 16.
[0250] FIG. 18 is a cross-section side view illustration of the
system and apparatus for aerosol delivery of FIG. 16.
[0251] FIG. 19 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiment of the second mode of the present
disclosure.
[0252] FIG. 20 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiment of the second
mode of the present disclosure.
[0253] FIG. 21 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiment of the second
mode of the present disclosure, in an alternative configuration
from that of FIG. 20.
[0254] FIG. 22 is a cross-section side view of aerosol carrier
according to one or more embodiment of the second mode of the
present disclosure.
[0255] FIG. 23 is a perspective cross-section side view of the
aerosol carrier of FIG. 22.
[0256] FIG. 24 is an exploded perspective view illustration of a
kit-of-parts for assembling the system according to one or more
embodiment of the second mode of the present disclosure.
[0257] FIG. 25 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiments of the third
mode of the present disclosure.
[0258] FIG. 26 is a cross-section side view illustration of part of
an apparatus of the system for aerosol delivery of FIG. 25.
[0259] FIG. 27 is a cross-section side view illustration of the
system and apparatus for aerosol delivery of FIG. 25.
[0260] FIG. 28 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiments of the third mode of the present
disclosure.
[0261] FIG. 29 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the third
mode of the present disclosure.
[0262] FIG. 30 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the third
mode of the present disclosure, in an alternative configuration
from that of FIG. 29.
[0263] FIG. 31 is a cross-section side view of aerosol carrier
according to one or more embodiments of the third mode of the
present disclosure.
[0264] FIG. 32 is a perspective cross-section side view of the
aerosol carrier of FIG. 31.
[0265] FIG. 33 is an exploded perspective view illustration of a
kit-of-parts for assembling the system according to one or more
embodiments of the third mode of the present disclosure.
[0266] FIG. 34 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiments of the fourth
mode of the present disclosure.
[0267] FIG. 35 is a cross-section side view illustration of part of
an apparatus of the system for aerosol delivery of FIG. 33.
[0268] FIG. 36 is a cross-section side view illustration of the
system and apparatus for aerosol delivery of FIG. 34.
[0269] FIG. 37 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiments of the fourth mode of the present
disclosure.
[0270] FIG. 38 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the fourth
mode of the present disclosure.
[0271] FIG. 39 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the fourth
mode of the present disclosure, in an alternative configuration
from that of FIG. 38.
[0272] FIG. 40 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the fourth
mode of the present disclosure, in an alternative configuration
from those of FIGS. 38 and 39.
[0273] FIG. 41 is a cross-section side view of aerosol carrier
according to one or more embodiments of the fourth mode of the
present disclosure.
[0274] FIG. 42 is a perspective cross-section side view of the
aerosol carrier of FIG. 41.
[0275] FIG. 43 is an exploded perspective view illustration of a
kit-of-parts for assembling the system according to one or more
embodiments of the fourth mode of the present disclosure.
[0276] FIG. 44 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiments of the fifth
mode of the present disclosure.
[0277] FIG. 45 is a cross-section side view illustration of part of
an apparatus of the system for aerosol delivery of FIG. 44.
[0278] FIG. 46 is a cross-section side view illustration of the
system and apparatus for aerosol delivery of FIG. 44.
[0279] FIG. 47 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiments of the fifth mode of the present
disclosure.
[0280] FIG. 48 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the fifth
mode of the present disclosure.
[0281] FIG. 49 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the fifth
mode of the present disclosure, in an alternative configuration
from that of FIG. 48.
[0282] FIG. 50 is a cross-section side view of aerosol carrier
according to one or more embodiments of the fifth mode of the
present disclosure.
[0283] FIG. 51 is a perspective cross-section side view of the
aerosol carrier of FIG. 50.
[0284] FIG. 52 is an exploded perspective view illustration of a
kit-of-parts for assembling the system according to one or more
embodiments of the fifth mode of the present disclosure.
[0285] FIG. 53 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiments of the sixth
mode of the present disclosure.
[0286] FIG. 54 is a cross-section side view illustration of part of
an apparatus of the system for aerosol delivery of FIG. 53.
[0287] FIG. 55 is a cross-section side view illustration of the
system and apparatus for aerosol delivery of FIG. 53.
[0288] FIG. 56 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiments of the sixth mode of the present
disclosure.
[0289] FIG. 57 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the sixth
mode of the present disclosure.
[0290] FIG. 58 is a cross-section side view of aerosol carrier
according to one or more embodiments of the sixth mode of the
present disclosure.
[0291] FIG. 59 is a perspective cross-section side view of the
aerosol carrier of FIG. 58.
[0292] FIG. 60 is an exploded perspective view illustration of a
kit-of-parts for assembling the system according to one or more
embodiments of the sixth mode of the present disclosure.
[0293] FIG. 61 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiments of the
seventh mode of the present disclosure.
[0294] FIG. 62 is a cross-sectional side view illustration of part
of an apparatus of the system for aerosol delivery of FIG. 61.
[0295] FIG. 63 is a cross-sectional side view illustration of the
system and apparatus for aerosol delivery of FIG. 61.
[0296] FIG. 64 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiments of the seventh mode of the present
disclosure.
[0297] FIG. 65 is a cross-section side view of elements of an
aerosol carrier and of part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the
seventh mode of the present disclosure.
[0298] FIG. 66 is a cross-section side view of elements of an
aerosol carrier and of part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the
seventh mode of the present disclosure.
[0299] FIG. 67 is a perspective view illustration of the aerosol
carrier and of part of an apparatus of the system for aerosol
delivery according to one or more embodiments of the seventh mode
of the present disclosure.
[0300] FIG. 68 is a perspective view illustration of the aerosol
carrier and of part of an apparatus of the system for aerosol
delivery according to one or more embodiments of the seventh mode
of the present disclosure.
[0301] FIG. 69 is a cross-section side view of an aerosol carrier
according to one or more embodiments of the seventh mode of the
present disclosure.
[0302] FIG. 70 is a perspective cross-section side view of the
aerosol carrier of FIG. 69.
[0303] FIG. 71 is an exploded perspective view illustration of a
kit-of-parts for assembling a system according to one or more
embodiments of the seventh mode of the present disclosure.
[0304] FIG. 72 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiments of the eighth
mode of the present disclosure.
[0305] FIG. 73 is a cross-section side view illustration of part of
an apparatus of the system for aerosol delivery of FIG. 72.
[0306] FIG. 74 is a cross-section side view illustration of the
system and apparatus for aerosol delivery of FIG. 72.
[0307] FIG. 75 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiments of the eighth mode of the present
disclosure.
[0308] FIG. 76 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the eighth
mode of the present disclosure.
[0309] FIG. 77 is a cross-section side view of aerosol carrier
according to one or more embodiments of the eighth mode of the
present disclosure.
[0310] FIG. 78 is a perspective cross-section side view of the
aerosol carrier of FIG. 78.
[0311] FIG. 79 is an exploded perspective view illustration of a
kit-of-parts for assembling the system according to one or more
embodiments of the eighth mode of the present disclosure.
[0312] FIG. 79 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiments of the ninth
mode of the present disclosure.
[0313] FIG. 80 is a cross-section side view illustration of part of
an apparatus of the system for aerosol delivery of FIG. 79.
[0314] FIG. 81 is a cross-section side view illustration of the
system and apparatus for aerosol delivery of FIG. 79.
[0315] FIG. 82 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiments of the ninth mode of the present
disclosure.
[0316] FIG. 83 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the ninth
mode of the present disclosure.
[0317] FIG. 84 is a cross-section side view of elements of an
aerosol carrier and a part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the ninth
mode of the present disclosure, in an alternative configuration
from that of FIG. 83.
[0318] FIG. 85 is a cross-section side view of aerosol carrier
according to one or more embodiments of the ninth mode of the
present disclosure.
[0319] FIG. 86 is a perspective cross-section side view of the
aerosol carrier of FIG. 85.
[0320] FIG. 87 is an exploded perspective view illustration of a
kit-of-parts for assembling the system according to one or more
embodiments of the ninth mode of the present disclosure.
[0321] FIG. 88 is a perspective view illustration of a system for
aerosol delivery according to one or more embodiments of the tenth
mode of the present disclosure.
[0322] FIG. 89 is a cross-sectional side view illustration of part
of an apparatus of the system for aerosol delivery of FIG. 88.
[0323] FIG. 90 is a cross-sectional side view illustration of the
system and apparatus for aerosol delivery of FIG. 88.
[0324] FIG. 91 is a perspective view illustration of an aerosol
carrier for use in the system for aerosol delivery according to one
or more embodiments of the tenth mode of the present
disclosure.
[0325] FIG. 92 is a cross-section side view of elements of an
aerosol carrier and of part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the tenth
mode of the present disclosure.
[0326] FIG. 93 is a cross-section side view of elements of an
aerosol carrier and of part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the tenth
mode of the present disclosure.
[0327] FIG. 94 is a perspective view illustration of the aerosol
carrier and of part of an apparatus of the system for aerosol
delivery according to one or more embodiments of the tenth mode of
the present disclosure.
[0328] FIG. 95 is a perspective view illustration of the aerosol
carrier and of part of an apparatus of the system for aerosol
delivery according to one or more embodiments of the tenth mode of
the present disclosure.
[0329] FIG. 96 is a perspective end view illustration of a
fluid-transfer article of the aerosol carrier according to one or
more embodiments of the tenth mode of the present disclosure.
[0330] FIG. 97 is a perspective end view illustration of a
fluid-transfer article of the aerosol carried according to one or
more embodiments of the tenth mode of the present disclosure.
[0331] FIG. 98 is a cross-section side view of an aerosol carrier
according to one or more embodiments of the tenth mode of the
present disclosure.
[0332] FIG. 99 is a perspective cross-section side view of the
aerosol carrier of FIG. 98.
[0333] FIG. 100 is an exploded perspective view illustration of a
kit-of-parts for assembling a system according to one or more
embodiments of the tenth mode of the present disclosure.
[0334] FIG. 101 is a cross-section side view of elements of an
aerosol carrier and of part of an apparatus of the system for
aerosol delivery according to one or more embodiments of the tenth
mode of the present disclosure.
[0335] FIG. 102 is a cross-section view of elements of an aerosol
carrier and of part of an apparatus of the system for aerosol
delivery according to one or more embodiments of the tenth mode of
the present disclosure.
[0336] FIG. 103 is a perspective view of a fluid-transfer article
of the system for aerosol delivery according to one or more
embodiments of the tenth mode of the present disclosure.
[0337] FIG. 104 shows a schematic drawing of a first arrangement of
a smoking substitute system of the eleventh mode.
[0338] FIG. 105 shows another schematic drawing of the first
arrangement of the smoking substitute system of the eleventh
mode.
[0339] FIG. 106 shows a schematic drawing of a second arrangement
of a smoking substitute system of the eleventh mode.
[0340] FIG. 107 shows another schematic drawing of the second
arrangement of the smoking substitute system of the eleventh
mode.
[0341] FIG. 108 shows a cutaway view of part of a third arrangement
of a smoking substitute system of the eleventh mode.
[0342] FIG. 109 shows a cross-sectional view of an arrangement of a
flavor pod of the eleventh mode.
[0343] FIG. 110 shows in detail parts of another arrangement of a
smoking substitute system of the eleventh mode.
[0344] FIG. 111 shows detail of the heater and the heater support
in the arrangement of FIG. 110 of the eleventh mode.
[0345] FIG. 112 shows another arrangement of a smoking substitute
system of the eleventh mode.
[0346] FIG. 113 shows detail of part of a smoking substitute system
of the eleventh mode.
[0347] FIG. 114 shows detail of a heater support which may be used
in a smoking substitute system of the eleventh mode.
[0348] FIG. 115 shows detail of an alternative heater support which
may be used in a smoking substitute system of the eleventh
mode.
[0349] FIG. 116 shows detail of a heater which may be used in a
smoking substitute system of the eleventh mode.
[0350] FIG. 117 shows yet another arrangement of a smoking
substitute system of the eleventh mode.
[0351] FIG. 118 shows a detailed schematic sectional view of a part
of a smoking substitute system of the eleventh mode.
[0352] FIG. 119 shows yet another arrangement of a smoking
substitute system of the eleventh mode.
[0353] FIG. 120 shows a consumable part of another smoking
substitute system of the eleventh mode.
[0354] FIG. 121 shows another consumable part of a smoking
substitute system of the eleventh mode.
[0355] FIG. 122 shows detail of the consumable part of FIG.
121.
DETAILED DESCRIPTION OF THE FIGURES
[0356] First Mode: An Aerosol-Generation Apparatus, Comprising a
Fluid-Transfer Article Having an Activation Surface and Configured
for Thermal Interaction with a Heating Surface
[0357] Aspects and embodiments of the first mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the first mode will be
apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0358] In general outline, one or more embodiments of the first
mode in accordance with the present disclosure may provide a system
for aerosol delivery in which an aerosol carrier may be inserted
into a receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier. Another end, or another end portion, of the aerosol
carrier may protrude from the apparatus and can be inserted into
the mouth of a user for the inhalation of aerosol released from the
aerosol carrier cartridge during operation of the apparatus.
[0359] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
[0360] Referring now to FIG. 1, there is illustrated a perspective
view of an aerosol delivery system 10 comprising an aerosol
generation apparatus 12 operative to initiate and maintain release
of aerosol from a fluid-transfer article in an aerosol carrier 14.
In the arrangement of FIG. 1, the aerosol carrier 14 is shown with
a first end 16 thereof and a portion of the length of the aerosol
carrier 14 located within a receptacle of the apparatus 12. A
remaining portion of the aerosol carrier 14 extends out of the
receptacle. This remaining portion of the aerosol carrier 14,
terminating at a second end 18 of the aerosol carrier, is
configured for insertion into a user's mouth. A vapor and/or
aerosol is produced when a heater (not shown in FIG. 1) of the
apparatus 12 heats a fluid-transfer article in the aerosol carrier
14 to release a vapor and/or an aerosol, and this can be delivered
to the user, when the user sucks or inhales, via a fluid passage in
communication with an outlet of the aerosol carrier 14 from the
fluid-transfer article to the second end 18.
[0361] The device 12 also comprises air-intake apertures 20 in the
housing of the apparatus 12 to provide a passage for air to be
drawn into the interior of the apparatus 12 (when the user sucks or
inhales) for delivery to the first end 16 of the aerosol carrier
14, so that the air can be drawn across an activation surface of a
fluid-transfer article located within a housing of the aerosol
carrier cartridge 14 during use. Optionally, these apertures may be
perforations in the housing of the apparatus 12.
[0362] A fluid-transfer article (not shown in FIG. 1, but described
hereinafter with reference to FIGS. 5, 6, 7, 8, 9, 10, 11 and 12)
is located within a housing of the aerosol carrier 14. The
fluid-transfer article contains an aerosol precursor material,
which may include at least one of: nicotine; a nicotine precursor
material; a nicotine compound; and one or more flavorings. The
fluid-transfer article is located within the housing of the aerosol
carrier 14 to allow air drawn into the aerosol carrier 14 at, or
proximal, the first end 16 to flow across an activation surface of
the fluid-transfer article. As air passes across the activation
surface of the fluid-transfer article, an aerosol may be entrained
in the air stream from a substrate forming the fluid-transfer
article, e.g., via diffusion from the substrate to the air stream
and/or via vaporization of the aerosol precursor material and
release from the fluid-transfer article under heating.
[0363] The substrate forming the fluid-transfer article 34
comprises a porous material where pores of the porous material
hold, contain, carry, or bear the aerosol precursor material. In
particular, the porous material of the fluid-transfer article may
be a polymeric wicking material such as, for example, a sintered
material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET). All such
materials may be described as heat resistant polymeric wicking
material in the context of the present disclosure.
[0364] The aerosol carrier 14 is removable from the apparatus 12 so
that it may be disposed of when expired. After removal of a used
aerosol carrier 14, a replacement aerosol carrier 14 can be
inserted into the apparatus 12 to replace the used aerosol carrier
14.
[0365] FIG. 2 is a cross-sectional side view illustration of a part
of apparatus 12 of the aerosol delivery system 10. The apparatus 12
comprises a receptacle 22 in which is located a portion of the
aerosol carrier 14. In one or more optional arrangements, the
receptacle 22 may enclose the aerosol carrier 14. The apparatus 12
also comprise a heater 24, which opposes an activation surface of
the fluid-transfer article (not shown in FIG. 2) of the aerosol
carrier 14 when an aerosol carrier 14 is located within the
receptacle 22.
[0366] Air flows into the apparatus 12 (in particular, into a
closed end of the receptacle 22) via air-intake apertures 20. From
the closed end of the receptacle 22, the air is drawn into the
aerosol carrier 14 (under the action of the user inhaling or
sucking on the second end 18) and expelled at the second end 18. As
the airflows into the aerosol carrier 14, it passes across the
activation surface of the fluid-transfer article. Heat from the
heater 24, which opposes the activation surface of the
fluid-transfer article, causes vaporization of aerosol precursor
material at the activation surface of the fluid-transfer article
and an aerosol is created in the air flowing over the activation
surface. Thus, through the application of heat in the region of the
activation surface of the fluid-transfer article, an aerosol is
released, or liberated, from the fluid-transfer article, and is
drawn from the material of the aerosol carrier unit by the air
flowing across the activation surface and is transported in the air
flow to via outlet conduits (not shown in FIG. 2) in the housing of
the aerosol carrier 14 to the second end 18. The direction of air
flow is illustrated by arrows in FIG. 2.
[0367] To achieve release of the captive aerosol from the
fluid-transfer article, the fluid-transfer article of the aerosol
carrier 14 is heated by the heater 24. As a user sucks or inhales
on second end 18 of the aerosol carrier 14, the aerosol released
from the fluid-transfer article and entrained in the air flowing
across the activation surface of the fluid-transfer article is
drawn through the outlet conduits (not shown) in the housing of the
aerosol carrier 14 towards the second end 18 and onwards into the
user's mouth.
[0368] Turning now to FIG. 3, a cross-sectional side view of the
aerosol delivery system 10 is schematically illustrated showing the
features described above in relation to FIGS. 1 and 2 in more
detail. As can be seen, apparatus 12 comprises a housing 26, in
which are located the receptacle 22 and heater 24. The housing 26
also contains control circuitry (not shown) operative by a user, or
upon detection of air and/or vapor being drawn into the device 12
through air-intake apertures 20, i.e., when the user sucks or
inhales. Additionally, the housing 26 comprises an electrical
energy supply 28, for example a battery.
[0369] Optionally, the battery comprises a rechargeable lithium-ion
battery. The housing 26 also comprises a coupling 30 for
electrically (and optionally mechanically) coupling the electrical
energy supply 28 to control circuitry (not shown) for powering and
controlling operation of the heater 24.
[0370] Responsive to activation of the control circuitry of
apparatus 12, the heater 24 heats the fluid-transfer article (not
shown in FIG. 3) of aerosol carrier 14. This heating process
initiates (and, through continued operation, maintains) release of
vapors and/or an aerosol from the activation surface of the
fluid-transfer article. The vapors and/or aerosol formed as a
result of the heating process is entrained into a stream of air
being drawn across the activation surface of the fluid-transfer
article (as the user sucks or inhales). The stream of air with the
entrained vapors and/or aerosol passes through the aerosol carrier
14 via outlet conduits (not shown) and exits the aerosol carrier 14
at second end 18 for delivery to the user.
[0371] This process is briefly described above in relation to FIG.
2, where arrows schematically denote the flow of the air stream
into the device 12 and through the aerosol carrier 14, and the flow
of the air stream with the entrained vapors and/or aerosol through
the aerosol carrier cartridge 14.
[0372] FIGS. 4 to 6 schematically illustrate the aerosol carrier 14
in more detail (and, in FIGS. 5 and 6, features within the
receptacle in more detail). FIG. 4 illustrates an exterior of the
aerosol carrier 14, FIG. 5 illustrates internal components of the
aerosol carrier 14 in an optional arrangement, and FIG. 6
illustrates internal components of the aerosol carrier 14 in
another optional arrangement.
[0373] FIG. 4 illustrates the exterior of the aerosol carrier 14,
which comprises housing 32 for housing said fluid-transfer article
(not shown) and at least one other internal component. The
particular housing 32 illustrated in FIG. 4 comprises a tubular
member, which may be generally cylindrical in form, and which is
configured to be received within the receptacle of the apparatus.
First end 16 of the aerosol carrier 14 is for location to oppose
the heater of the apparatus, and second end 18 (and the region
adjacent the second end 18) is configured for insertion into a
user's mouth.
[0374] FIG. 5 illustrates some internal components of the aerosol
carrier 14 and of the heater 24 of apparatus 12.
[0375] As described above, the aerosol carrier 14 comprises a
fluid-transfer article 34. The aerosol carrier 14 optionally may
comprise a conduction element 36 (as shown in FIG. 5). In one or
more arrangements, the aerosol carrier 14 is located within the
receptacle of the apparatus such that the activation surface of the
fluid-transfer article opposes the heater of the apparatus and
receives heat directly from the heater of the apparatus. In an
optional arrangement, such as illustrated in FIG. 5 for example,
the aerosol carrier 14 comprises a conduction element 36. When
aerosol carrier 14 is located within the receptacle of the
apparatus such that the activation surface of the fluid-transfer
article is located to oppose the heater of the apparatus, the
conduction element is disposed between the heater 24 and the
activation surface of the fluid-transfer article. Heat may be
transferred to the activation surface via conduction through
conduction element 36 (i.e., application of heat to the activation
surface is indirect).
[0376] Further components not shown in FIG. 5 and FIG. 6 (see FIGS.
11 and 12) comprise: an inlet conduit, via which air can be drawn
into the aerosol carrier 14; an outlet conduit, via which an air
stream entrained with aerosol can be drawn from the aerosol carrier
14; a filter element; and a reservoir for storing aerosol precursor
material and for providing the aerosol precursor material to the
fluid-transfer article 34.
[0377] In FIGS. 5 and 6, aerosol carrier is shown as comprising the
fluid-transfer article 34 located within housing 32. The material
forming the fluid transfer article 34 comprises a porous structure,
where pore diameter size varies between one end of the
fluid-transfer article 34 and another end of the fluid-transfer
article. In the illustrative examples of FIGS. 5 and 6, the pore
diameter size gradually decreases from a first end remote from
heater 24 (the upper end as shown in the figure) to a second end
proximal heater 24 (the lower end as shown in the figure). Although
the figure illustrates the pore diameter size changing in a
step-wise manner from the first to the second end (i.e., a first
region with pores having a diameter of a first size, a second
region with pores having a diameter of a second, smaller size, and
a third region with pores having a diameter of a third, yet smaller
size), the change in pore size from the first end to the second end
may be gradual rather than step-wise. This configuration of pores
having a decreasing diameter size from the first end and second end
can provide a wicking effect, which can serve to draw fluid from
the first end to the second end of the fluid-transfer article
34.
[0378] The fluid-transfer article 34 comprises a first region 34a
for holding an aerosol precursor. In one or more arrangements, the
first region 34a of the fluid-transfer article 34 comprises a
reservoir for holding the aerosol precursor. The first region 34a
can be the sole reservoir of the aerosol carrier 14, or it can be
arranged in fluid communication with a separate reservoir, where
aerosol precursor is stored for supply to the first region 34a.
[0379] The fluid-transfer article 34 also comprises a second region
34b. Aerosol precursor is drawn from the first region 34a to the
second region 34b by the wicking effect of the substrate material
forming the fluid transfer article. Thus, the first region 34a is
configured to transfer the aerosol precursor to the second region
34b of the article 34.
[0380] At the second end of fluid-transfer article 34, the surface
of the second region 34b defines an activation surface 38, which is
disposed opposite a surface for conveying heat to the activation
surface 38. In the illustrative examples of FIGS. 5 and 6, the
opposing surface for conveying heat to the activation surface 38
comprises part of the heater 24 being a substrate 35 which has
heating elements 36 thereon. The elements 36 will be powered
individually, or may be connected together so that they are powered
together. The heating elements 36 generate heat, when they are
activated. Thus, those heating elements are located for thermal
interaction with the second region 34b, and arranged to transfer
heat from the activation surface 38.
[0381] The activation surface 38 is discontinuous such that at
least one channel 40 is formed between the activation surface 38
and the heater 24. In some arrangements, the discontinuities may be
such that the activation surface 38 is undulating.
[0382] In the illustrative examples of FIGS. 5 and 6, the
activation surface 38 comprises a plurality of groove or valleys
therein to form an undulating surface, the grooves or valleys being
disposed in a parallel arrangement across the activation surface
38. Thus, there are a plurality of channels 40 between the
activation surface 38 and the heater 24.
[0383] In the illustrative example of FIG. 5, the grooves or
valleys in the activation surface 38 provide alternating peaks and
troughs that give rise to a "saw-tooth" type profile. In one or
more optional arrangements, the activation surface may comprise a
"castellated" type profile (i.e., a "square wave" type profile),
for example, such as illustrated in the example of FIG. 6. In one
or more optional arrangements, the activation surface may comprise
a "sinusoidal" type profile. The profile may comprise a mixture of
two or more of the above profiles given as illustrative
examples.
[0384] As can be seen in FIGS. 5 and 6 the heating elements are not
aligned with the channels 40, but instead are aligned with the
parts of the activation surface between the grooves or valleys,
i.e., the parts of the second region 34b which are closest to the
heater 24. There may be direct contact between those parts of the
second region 34b and the heating elements 36. The heating elements
36 thus heat the activation surface 38 at the walls between the
troughs or valleys, rather than being aligned with the troughs or
valleys themselves. Heat may then reach the rest of the activation
surface 38 by conduction through the second region 34b and also by
radiation across the channels 40.
[0385] In the illustrative examples of FIGS. 5 and 6, the first
region 34a of the fluid-transfer article 34 is located at an
"upstream" end of the fluid-transfer article 34 and the second
region 34b is located at a downstream" end of the fluid-transfer
article 34. That is, aerosol precursor is wicked, or is drawn, from
the "upstream" end of the fluid-transfer article 34 to the
"downstream" end of the fluid-transfer article 34 (as denoted by
arrow A in FIG. 5).
[0386] The aerosol precursor is configured to release an aerosol
and/or vapor upon heating. Thus, when the activation surface 38
receives heat conveyed from heater 24, the aerosol precursor held
at the activation surface 38 is heated. The aerosol precursor,
which is captively held in material of the fluid-transfer article
at the activation surface 38 is released into an air stream flowing
through the channels 40 between the heater 24 and activation
surface 38 as an aerosol and/or vapor.
[0387] The shape and/or configuration of the activation surface 38
and the associated shape(s) and/or configuration(s) of the one or
more channels 40 formed between the activation surface 38 and
heater 24 permit air to flow across the activation surface 38
(through the one or more channels 40) and also increase the surface
area of the activation surface 38 of the fluid-transfer article 34
that is available for contact with a flow of air across the
activation surface 38.
[0388] FIGS. 7 and 8 show perspective view illustrations of the
fluid-transfer article 34 of aerosol carrier and a heater 24 of the
apparatus of the system for aerosol delivery. In particular, these
figures illustrate air flows across the activation surface 38 when
the apparatus is in use in a first arrangement of the
fluid-transfer article 34 (see FIG. 7), and in a second arrangement
of the fluid-transfer article 34 (see FIG. 8).
[0389] In the illustrated example of use of the apparatus
schematically illustrated in FIG. 7, when a user sucks on a
mouthpiece of the apparatus, air is drawn into the carrier through
inlet apertures (not shown) provided in a housing of the carrier.
An incoming air stream 42 is directed to the activation surface 38
of the fluid-transfer article 34 (e.g., via a fluid communication
pathway within the housing of the carrier). When the incoming air
stream 42 reaches a first side of the activation surface 38, the
incoming air stream 42 flows across the activation surface 38 via
the one or more channels 40 formed between the activation surface
38 and heater 24. The air stream flowing through the one or more
channels 40 is denoted by dashed line 44 in FIG. 7. As the air
stream 44 flows through the one or more channels 40, aerosol
precursor at activation surface 38, across which the air stream 44
flows, is released from the activation surface 38 by heat conveyed
to the activation surface from the heater 24. Aerosol precursor
released from the activation surface 38 in this manner is then
entrained in the air stream 44 flowing through the one or more
channels 40.
[0390] In use, the heater 24 of the apparatus 12 conveys heat to
the fluid transfer article 34 to raise the temperature of the
activation surface 38 to a sufficient temperature to release, or
liberate, captive substances (i.e., the aerosol precursor) held at
the activation surface 38 of the fluid-transfer article 34 to form
a vapor and/or aerosol, which is drawn downstream across the
activation surface 38 of the fluid-transfer article. As the air
stream 44 continues its passage in the one or more channels 40,
more released aerosol precursor is entrained within the air stream
44. When the air stream 44 entrained with aerosol precursor exits
the one or more channels 40 at a second side of the activation
surface 38, it is directed to an outlet, from where it can be
inhaled by the user via a mouthpiece. An outgoing air stream 46
entrained with aerosol precursor is directed to the outlet (e.g.,
via a fluid communication pathway within the housing of the
carrier).
[0391] Therefore, operation of the apparatus will cause heat from
the heater 24 to be conveyed to the activation surface 38 of the
fluid-transfer article. At a sufficiently high temperature, captive
substances held at the activation surface 38 of the fluid-transfer
article 34 are released, or liberated, to form a vapor and/or
aerosol. Thus, when a user draws on a mouthpiece of the apparatus,
the released substances from the fluid-transfer article are drawn
away from the activation surface 38 (entrained in a stream of air)
and condense to form an aerosol that is drawn through the gas
communication pathway for delivery to an outlet, which is in fluid
communication with the mouthpiece.
[0392] As the aerosol precursor is released from the activation
surface 38, a wicking effect of the fluid-transfer article 34
causes aerosol precursor within the body of the fluid-transfer
article to migrate to the activation surface 38 to replace the
aerosol precursor released from the activation surface 38 into air
stream 44.
[0393] Operation of the heater 24 is controlled by control
circuitry (not shown), which is operable to actuate the heater 24
responsive to an actuation signal from a switch operable by a user
or configured to detect when the user draws air through a
mouthpiece of the apparatus by sucking or inhaling. In an optional
arrangement, the control circuitry operates to actuate the heater
24 with as little delay as possible from receipt of the actuation
signal from the switch, or detection of the user drawing air
through the mouthpiece. This may affect near instantaneous heating
of the activation surface 38 of the fluid-transfer article 34.
[0394] In the illustrated example of use of the apparatus
schematically illustrated in FIG. 8, rather than the case of FIG.
7, where air is drawn toward the activation surface 38 from one
side only (and exits from the one or more channels 40 at an
opposite side), a gas communication pathway for an incoming air
stream is configured to deliver the incoming air stream to the
activation surface 38 from both sides of the fluid-transfer
article, and thus from both ends of the channels 40 formed therein.
In such an arrangement, a gas communication pathway for an outlet
airstream may be provided through the body of the fluid-transfer
article 34. An outlet fluid communication pathway for an outlet
airstream in the illustrative example of FIG. 8 is denoted by
reference number 48. Thus, in the illustrative example of FIG. 8,
when a user draws on a mouthpiece of the apparatus, air is drawn
into the carrier 14 through inlet apertures (not shown) provided in
a housing of the carrier. An incoming air stream 42a from a first
side is directed to a first side of the activation surface 38 of
the fluid-transfer article 34 (e.g., via a gas communication
pathway within the housing of the carrier 14).
[0395] An incoming air stream 42b from a second side is directed to
a second side of the activation surface 38 of the fluid-transfer
article 34 (e.g., via a gas communication pathway within the
housing of the carrier 14). When the incoming air stream 42a from
the first side reaches the first side of the activation surface 38,
the incoming air stream 42a flows across the activation surface 38
via the one or more channels 40 formed between the activation
surface 38 and the heater 24. Likewise, when the incoming air
stream 42b from the second side reaches the second side of the
activation surface 38, the incoming air stream 42b flows across the
activation surface 38 via the one or more channels 40 formed
between the activation surface 38 and the heater 24. The air
streams 42a, 42b from each side flowing through the one or more
channels 40 are denoted by dashed lines 44a and 44b in FIG. 8. As
air streams 44a and 44b flow through the one or more channels 40,
aerosol precursor in the activation surface 38, across which the
airstreams 44a and 44b flow, is released from the activation
surface 38 by heat conveyed to the activation surface from the
heater 24. Aerosol precursor released from the activation surface
38 is entrained in air streams 44a and 44b flowing through the one
or more channels 40.
[0396] In use, the heater 24 of the apparatus 12 conveys heat to
the fluid-transfer article 34 to raise a temperature of the
activation surface 38 to a sufficient temperature to release, or
liberate, captive substances (i.e., the aerosol precursor) held at
the activation surface 38 of the fluid-transfer article 34 to form
a vapor and/or aerosol, which is drawn downstream across the
activation surface 38 of the fluid-transfer article. As the air
streams 44a and 44b continue their passages in the one or more
channels 40, more released aerosol precursor is entrained within
the air streams 44a and 44b. When the air streams 44a and 44b
entrained with aerosol precursor meet at a mouth of the outlet
fluid communication pathway 48, they enter the outlet fluid
communication pathway 48 and continue until they exit outlet fluid
communication pathway 48, either as a single outgoing air stream 46
(as shown), or as separate outgoing air streams. The outgoing air
stream 46 is directed to an outlet, from where it can be inhaled by
the user via a mouthpiece. The outgoing air stream 46 entrained
with aerosol precursor is directed to the outlet (e.g., via a gas
communication pathway within the housing of the carrier 14).
[0397] It should be noted that, in FIGS. 7 and 8, heater 24 similar
to that in FIGS. 5 and 6, with a substrate 35 on which are formed
heating elements 36. Those heating elements are not aligned with
the channels 40, but are aligned with the walls between those
channels 40.
[0398] FIGS. 9 and 10 are perspective end view illustrations of a
fluid-transfer article 34 of the aerosol carrier according to one
or more arrangements. These figures show different types of channel
configurations as illustrative examples. In both illustrative
examples of a channel configuration, as shown in FIGS. 9 and 10,
the fluid-transfer article 34 comprises a cylindrical member, which
comprises a central bore extending therethrough for fluid
communication between the activation surface 38 and an outlet, from
where an outgoing air stream can be delivered for inhalation. The
central bore serves as a fluid communication pathway 48 (e.g., as
described above in relation to FIG. 9). Note that, in the
arrangements of FIGS. 9 and 10, the channels 40 extend radially and
the sectional views of FIGS. 9 and 10 are along the length of two
channels on opposite radial positions relative to the central bore
of the fluid-transfer article. The heating elements 36 are
therefore not visible in FIGS. 9 and 10, although they will be in
similar positions, relative to the channels, as the heating
elements 36 and channels in FIGS. 5 to 8.
[0399] In both illustrative examples of FIGS. 9 and 10, an incoming
air stream 42 is directed to a mouth of a channel 40 formed between
the activation surface 38 of the fluid-transfer article 34 and
conduction element (not shown), or between the activation surface
38 and a heater (not shown). In both illustrative examples of FIGS.
9 and 10, the mouth of the channel 40 is located at an outer edge
of the fluid-transfer article 34 and an exit from the channel 40
(in fluid communication with the fluid communication pathway 48) is
located toward a center of the fluid-transfer article. Therefore,
the incoming air stream 42 enters the channel 40 via channel mouth
at the outer edge of the fluid-transfer article 34 and moves toward
the center of the fluid-transfer article 34 as directed by the
channel 40. As described above, as the air stream passes across
activation surface 38 through channel 40, aerosol precursor is
released from the activation surface 38 and is entrained in air
stream 44. Air stream 44 continues to flow through the channel 40
until it reaches an exit thereof, from where it enters the fluid
communication pathway 48 and proceeds as an outgoing air stream 46
entrained with aerosol precursor toward the outlet.
[0400] In both illustrative examples of FIGS. 9 and 10, the valleys
or grooves of the activation surface 38 that form part of the
channel 40 are arranged to define a circuitous route 20 across the
activation surface. In the illustrative examples, the route is a
spiral path, but in optional arrangements, may be meandering or
circuitous in some other manner. In optional arrangements, the
activation surface may be located to face outwardly from the
cylinder, such that the groove(s) or valley(s) may be in the outer
surface of the cylinder forming the fluid-transfer article. These
grooves or valleys may be arranged in parallel in a direction along
the length of the cylinder. The groove(s) or valley(s) may be
arranged in a spiral manner around the outside of the cylinder. In
optional arrangements, the activation surface 38 may be located to
face inwardly from the cylinder (i.e., surrounding the central
bore), such that the groove(s) or valley(s) maybe in the inner
surface of the cylinder forming the fluid-transfer article 34.
These grooves or valleys may be arranged in parallel in a direction
along the length of the cylinder. The groove(s) or valley(s) may be
arranged in a spiral manner around the inside of the cylinder.
[0401] With the arrangement shown in FIGS. 9 and 10, the heating
elements of the heater are therein not aligned with the valleys or
grooves in the activation surface 38. Instead, they will be aligned
with the projecting wall 45 of the activation surface 38, between
which walls 45 the valleys or grooves are formed. FIGS. 11 and 12
illustrate an aerosol carrier 14 according to one or more possible
arrangements in more detail. FIG. 11 is a cross-section side view
illustration of the aerosol carrier 14 and FIG. 12 is a perspective
cross-section side view illustration of the aerosol carrier 14 of
FIG. 11. In FIGS. 11 and 12, the structure of the heater 24 is not
illustrated in detail. However, it may correspond to, e.g., one of
the arrangements of FIGS. 5 to 8, with a heater 24 having a
substrate 35 on which heating elements 36 are formed which are not
aligned with the channels 40, and instead are aligned with the
parts of the activation surface between those channels 40.
[0402] As can be seen from FIGS. 11 and 12, the aerosol carrier 14
is generally tubular in form. The aerosol carrier 14 comprises
housing 32, which defines the external walls of the aerosol carrier
14 and which defines therein a chamber in which are disposed the
fluid-transfer article 34 (adjacent the first end 16 of the aerosol
carrier 14) and internal walls defining the fluid communication
pathway 48. Fluid communication pathway 48 defines a fluid pathway
for an outgoing air stream from the channels 40 to the second end
18 of the aerosol carrier 14. In the examples illustrated in FIGS.
11 and 12, the fluid-transfer article 34 is an annular shaped
element located around the fluid communication pathway 48, and the
channels 40 are arranged so as to extend radially across its
activation surface.
[0403] In walls of the housing 32, there are provided inlet
apertures 50 to provide a fluid communication pathway for an
incoming air stream to reach the fluid-transfer article 34, and
particularly the one or more channels 40 defined between the
activation surface of the fluid-transfer article 34 and the heater
24.
[0404] In the illustrated example of FIGS. 11 and 12, the aerosol
carrier 14 further comprises a filter element 52. The filter
element 52 is located across the fluid communication pathway 48
such that an outgoing air stream passing through the fluid
communication pathway 48 passes through the filter element 52.
[0405] With reference to FIG. 12, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18 of the aerosol carrier
14, if configured as a mouthpiece), air is drawn into the carrier
through inlet apertures 50 extending through walls in the housing
32 of the aerosol carrier 14. An incoming air stream 42a from a
first side of the aerosol carrier 14 is directed to a first side of
the activation surface 38 of the fluid-transfer article 34 (e.g.,
via a gas communication pathway within the housing of the carrier).
An incoming air stream 42b from a second side of the aerosol
carrier 14 is directed to a second side of the activation surface
38 of the fluid-transfer article 34 (e.g., via a gas communication
pathway within the housing of the carrier). When the incoming air
stream 42a from the first side of the aerosol carrier 14 reaches
the first side of the activation surface 38, the incoming air
stream 42a from the first side of the aerosol carrier 14 flows
across the activation surface 38 via the one or more channels 40
formed between the activation surface 38 and the conduction element
36 (or between the activation surface 38 and heater 24). Likewise,
when the incoming air stream 42b from the second side of the
aerosol carrier 14 reaches the second side of the activation
surface 38, the incoming air stream 42b from the second side of the
aerosol carrier 14 flows across the activation surface 38 via the
one or more channels 40 formed between the activation surface 38
and the conduction element 36 (or between the activation surface 38
and heater 24). The air streams from each side flowing through the
one or more channels 40 are denoted by dashed lines 44a and 44b in
FIG. 12. As air streams 44a and 44b flow through the one or more
channels 40, aerosol precursor in the activation surface 38, across
which the air streams 44a and 44b flow, is released from the
activation surface 38 by heat conveyed to the activation surface
from the heater 24. Aerosol precursor released from the activation
surface 38 is entrained in air streams 44a and 44b flowing through
the one or more channels 40.
[0406] In use, the heater 24 of the apparatus 12 conveys heat to
the activation surface 38 of the fluid-transfer article 34 to raise
a temperature of the activation surface 38 to a sufficient
temperature to release, or liberate, captive substances (i.e., the
aerosol precursor) held at the activation surface 38 of the
fluid-transfer article 34 to form a vapor and/or aerosol, which is
drawn downstream across the activation surface 38 of the
fluid-transfer article 34. As the air streams 44a and 44b continue
their passages in the one or more channels 40, more released
aerosol precursor is entrained within the air streams 44a and 44b.
When the air streams 44a and 44b entrained with aerosol precursor
meet at a mouth of the outlet fluid communication pathway 48, they
enter the outlet fluid communication pathway 48 and continue until
they pass through filter element 52 and exit outlet fluid
communication pathway 48, either as a single outgoing air stream,
or as separate outgoing air streams 46 (as shown). The outgoing air
streams 46 are directed to an outlet, from where it can be inhaled
by the user directly (if the second end 18 of the aerosol capsule
14 is configured as a mouthpiece), or via a mouthpiece. The
outgoing air streams 46 entrained with aerosol precursor are
directed to the outlet (e.g., via a gas communication pathway
within the housing of the carrier).
[0407] When the user initially draws on a mouthpiece of the
apparatus (or one the second end 18 of the aerosol carrier 14, if
configured as a mouthpiece), this will cause an air column located
in the fluid communication pathway 48 to move towards the outlet.
In turn, this will draw air into the fluid communication pathway
from the one or more channels 40. This will cause a pressure drop
in the channels 40. To equalize the pressure in the channels 40,
air will be drawn into the aerosol carrier 14, and thus into the
channels 40 via the inlet apertures 50. During the period of lower
pressure in the one or more channels 40 when the user begins to
draw, aerosol precursor in the fluid-transfer medium will be
released into the channels from the activation surface 38, because
the aerosol precursor is drawn into the one or more channels by way
of the lower pressure. This effect is in addition to the effect of
releasing the aerosol precursor from the activation surface 38 by
way of heat conveyed from the heater. The drawing of the aerosol
precursor from the activation surface 38 by way of the user sucking
on the mouthpiece of the apparatus (or one the second end 18 of the
aerosol carrier 14, if configured as a mouthpiece) may produce a
dragging effect on the volumetric rate of flow experienced by the
user during a suction action, i.e., the user may have to suck
harder to achieve a same volumetric rate of flow. This effect may
manifest itself as a similar physical sensation experienced by the
user as those experienced from a traditional smoking or tobacco
product. FIG. 13 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10.
[0408] As will be appreciated, in the arrangements described above,
the fluid-transfer article 34 is provided within a housing 32 of
the aerosol carrier 14. In such arrangements, the housing of the
carrier 14 serves to protect the aerosol precursor-containing
fluid-transfer article 34, whilst also allowing the carrier 14 to
be handled by a user without his/her fingers coming into contact
with the aerosol precursor liquid retained therein. In such
arrangements, it will be appreciated that the carrier 14 has a
multi-part construction. In some cases, this might be considered
somewhat disadvantageous because it requires a relatively
complicated assembly procedure which can be both time-consuming and
expensive. Turning now to consider FIG. 14, there is illustrated
another possible aspect of the first mode of the fluid-transfer
article 34, which may be employed in some arrangements, and which
may permit the creation of a significantly simplified carrier
14.
[0409] FIG. 14 illustrates an alternative fluid-transfer article 34
in position adjacent a planar heater 24, such that the air flow
channels 40 are positioned between the activation surface 38 and
the heater 24. In the arrangement of FIG. 14, the substrate forming
the fluid-transfer article 34 again comprises a porous material
where pores of the porous material hold, contain, carry, or bear
the aerosol precursor material. Itis envisaged, for example, that
the same types of substrate material may be used in the arrangement
illustrated in FIG. 14 as in the previously-described arrangements.
In particular, therefore, the porous material of the fluid-transfer
article 34 may be a polymeric wicking material. However, in the
arrangement illustrated in FIG. 14, the substrate material includes
an integrally formed peripheral wall 54.
[0410] It is proposed that the peripheral wall 54 may be formed by
treating the outermost surface of the porous substrate material of
the fluid-transfer article 34 so as to render the surface
substantially liquid-impermeable. For example, it is envisaged that
in some arrangements the substrate material may be locally heated
so as to fuse the material and close up its internal pores in the
localized region of the surface. Alternatively, it is envisaged
that the substrate material may be treated by a sintering process
in order to create the liquid-impermeable peripheral wall 54.
[0411] The peripheral wall 54 may alternatively be created by a
chemical treatment process to render the substrate material
substantially liquid-impermeable in the region of its outermost
surface. As will therefore be appreciated, the peripheral wall 54
may be considered to take the form of a skin formed from the
material of the substrate itself. The peripheral wall may be
created in this manner so as to substantially completely
circumscribe the substrate material. It is to be appreciated,
however, that the activation surface 38 of the fluid-transfer
article 34 will not be treated in this manner, thereby ensuring
that it will retain the function described above in detail in
cooperation with the heater 24.
[0412] The thickness of the peripheral wall 54 formed from the
substrate may vary depending on the desired physical properties of
the fluid-transfer article 34. For example, a relatively thin wall
54 might be desirable in some circumstances, as this may retain
some flexibility in the material, thereby providing a
fluid-transfer article which will feel soft in the hands of a user.
Alternatively, a relatively thick peripheral wall 54 might be
desirable in arrangements where the wall 54 is required to provide
some structural rigidity to the fluid-transfer article 34. The wall
54 may therefore have a thickness of less than 3 mm; or less than
2.5 mm; or less than 2 mm; or less than 1.5 mm; or less than 1 mm;
or less than 0.9 mm; or less than 0.8 mm; or less than 0.7 mm; or
less than 0.6 mm; or less than 0.5 mm; or less than 0.4 mm; or less
than 0.3 mm; or less than 0.2 mm; or less than 0.1 mm in some
embodiments of the first mode. As will be appreciated, the
liquid-impermeable nature of the resulting peripheral wall or skin
means that the fluid-transfer article 34 may be handled by a user
without getting his or her fingers wet from the aerosol precursor
liquid retained therein. This opens up the possibility of the
fluid-transfer article 34 being used without an enclosing housing
32, as was necessary in the previously-described arrangements. It
is therefore envisaged that in some arrangements, the
fluid-transfer article 34 may itself define an entire aerosol
carrier 14. Furthermore, it is envisaged that in some embodiments
of the first mode, a fluid-transfer article 34 in accordance with
this proposal may be provided in the form of a unitary monolithic
element of substrate material and could, therefore, take the form
of a single-piece consumable or carrier 14 for an aerosol-delivery
system 10, which may be provided pre-filled with aerosol precursor
liquid and which may be discarded when the initial volume of
precursor has been used. A single-piece consumable of this type
offers very significant advantages in terms of cost of manufacture,
and from an environmental point of view.
[0413] In order to illustrate the electrical connection of the
heating elements 36, FIG. 15 shows an arrangement corresponds to
FIG. 14, but in a perspective view, with part of the fluid-transfer
article shown transparent (in reality, it will not be transparent).
FIG. 15 thus illustrates the channels 40 and the heating elements
36 which are aligned with the walls of the second region 34b on
either side of the channels 40. FIG. 15 also illustrates electrical
contacts 37a and 37b on the substrate 35, which are connected to
the heating elements 36 and which are connected to a source of
electrical power for heating the heating elements 36. Conductive
strips 37c then connect the terminals 37a and 37b with the heating
elements 36, and connect the heating elements 36 to each other. The
connection is such that the heating elements and conductive strips
37c form a zig-zag arrangement along the substrate 35. Other parts
of the structure of FIG. 15 correspond to those shown in FIG.
14.
[0414] The porous layer may have a thickness of less than 5 mm. In
other embodiments of the first mode it may have a thickness of:
less than 3.5 mm, less than 3 mm, less than 2.5 mm, less than 2 mm,
less than 1.9 mm, less than 1.8 mm, less than 1.7 mm, less than 1.6
mm, less than 1.5 mm, less than 1.4 mm, less than 1.3 mm, less than
1.2 mm, less than 1.1 mm, less than 1 mm, less than 0.9 mm, less
than 0.8 mm, less than 0.7 mm, less than 0.6 mm, less than 0.5 mm,
less than 0.4 mm, less than 0.3 mm, less than 0.2 mm, or less than
0.1 mm.
[0415] There has been described in the foregoing one or more
proposals for an aerosol delivery system, and parts thereof, that
avoids or at least ameliorates problems of the prior art.
[0416] In one or more optional arrangements of the first mode, a
fluid-transfer article 34 containing nicotine and/or nicotine
compounds may be substituted or supplemented with a fluid-transfer
article configured to provide a flavored vapor and/or aerosol upon
heating of the fluid-transfer article by the heater 24 of the
apparatus 12. A precursor material for forming the flavored vapor
and/or aerosol upon heating is held within pores, spaces, channels
and/or conduits within the fluid-transfer article. The precursor
material may be extracted from a tobacco plant starting material
using a supercritical fluid extraction process. Optionally, the
precursor material is nicotine-free and comprises tobacco-flavors
extracted from the tobacco plant starting material. Further
optionally, the extracted nicotine-free precursor material (e.g.,
flavors only) could have nicotine added thereto prior to loading of
the precursor material into the substrate of the carrier unit.
Further optionally, flavors and physiologically active material may
be extracted from plants other than tobacco plants.
[0417] Second Mode: An Aerosol-Generation Apparatus has a
Fluid-Transfer Article which Holds and Transfers Aerosol Precursor
to an Activation Surface
[0418] Aspects and embodiments of the second mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the second mode will be
apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0419] In general outline, one or more embodiments in accordance
with the present disclosure may provide a system for aerosol
delivery in which an aerosol carrier may be inserted into a
receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier. Another end, or another end portion, of the aerosol
carrier may protrude from the apparatus and can be inserted into
the mouth of a user for the inhalation of aerosol released from the
aerosol carrier cartridge during operation of the apparatus.
[0420] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
Referring now to FIG. 16, there is illustrated a perspective view
of an aerosol delivery system 10-2 comprising an aerosol generation
apparatus 12-2 operative to initiate and maintain release of
aerosol from a fluid-transfer article in an aerosol carrier 14-2.
In the arrangement of FIG. 16, the aerosol carrier 14-2 is shown
with a first end 16-2 thereof and a portion of the length of the
aerosol carrier 14-2 located within a receptacle of the apparatus
12-2. A remaining portion of the aerosol carrier 14-2 extends out
of the receptacle. This remaining portion of the aerosol carrier
14-2, terminating at a second end 18-2 of the aerosol carrier, is
configured for insertion into a user's mouth. A vapor and/or
aerosol is produced when a heater (not shown in FIG. 16) of the
apparatus 12-2 heats a fluid-transfer article in the aerosol
carrier 14-2 to release a vapor and/or an aerosol, and this can be
delivered to the user, when the user sucks or inhales, via a fluid
passage in communication with an outlet of the aerosol carrier 14-2
from the fluid-transfer article to the second end 18-2.
[0421] The device 12-2 also comprises air-intake apertures 20-2 in
the housing of the apparatus 12-2 to provide a passage for air to
be drawn into the interior of the apparatus 12-2 (when the user
sucks or inhales) for delivery to the first end 16-2 of the aerosol
carrier 14-2, so that the air can be drawn across an activation
surface of a fluid-transfer article located within a housing of the
aerosol carrier cartridge 14-2 during use. Optionally, these
apertures may be perforations in the housing of the apparatus
12-2.
[0422] A fluid-transfer article (not shown in FIG. 16, but
described hereinafter with reference to FIGS. 20 to 23) is located
within a housing of the aerosol carrier 14-2. The fluid-transfer
article contains an aerosol precursor material, which may include
at least one of: nicotine; a nicotine precursor material; a
nicotine compound; and one or more flavorings. The fluid-transfer
article is located within the housing of the aerosol carrier 14-2
to allow air drawn into the aerosol carrier 14-2 at, or proximal,
the first end 16-2 to flow across an activation surface of the
fluid-transfer article. As air passes across the activation surface
of the fluid-transfer article, an aerosol may be entrained in the
air stream from a substrate forming the fluid-transfer article,
e.g., via diffusion from the substrate to the air stream and/or via
vaporization of the aerosol precursor material and release from the
fluid-transfer article under heating. The substrate forming the
fluid-transfer article 34-2 comprises a porous material where pores
of the porous material hold, contain, carry, or bear the aerosol
precursor material. In particular, the porous material of the
fluid-transfer article is a porous polymer material such as, for
example, a sintered material. Particular examples of material
suitable for the fluid-transfer article include: Polyetherimide
(PEI); Polytetrafluoroethylene (PTFE); Polyether ether ketone
(PEEK); Polyimide (PI); Polyethersulphone (PES); and Ultra-High
Molecular Weight Polyethylene. Other suitable materials may
comprise, for example, BioVyon.TM. (by Porvair Filtration Group
Ltd) and materials available from Porex.COPYRGT.. Further
optionally, a substrate forming the fluid-transfer article may
comprise Polypropylene (PP) or Polyethylene Terephthalate (PET).
All such materials may be described as heat resistant polymeric
wicking material in the context of the present disclosure.
[0423] The aerosol carrier 14-2 is removable from the apparatus
12-2 so that it may be disposed of when expired. After removal of a
used aerosol carrier 14-2, a replacement aerosol carrier 14-2 can
be inserted into the apparatus 12-2 to replace the used aerosol
carrier 14-2.
[0424] FIG. 17 is a cross-sectional side view illustration of a
part of apparatus 12-2 of the aerosol delivery system 10. The
apparatus 12-2 comprises a receptacle 22-2 in which is located a
portion of the aerosol carrier 14-2. In one or more optional
arrangements, the receptacle 22-2 may enclose the aerosol carrier
14-2. The apparatus 12-2 also comprise a heater 24-2, which opposes
an activation surface of the fluid-transfer article (not shown in
FIG. 17) of the aerosol carrier 14-2 when an aerosol carrier 14-2
is located within the receptacle 22-2.
[0425] Air flows into the apparatus 12-2 (in particular, into a
closed end of the receptacle 22-2) via air-intake apertures 20-2.
From the closed end of the receptacle 22-2, the air is drawn into
the aerosol carrier 14-2 (under the action of the user inhaling or
sucking on the second end 18-2) and expelled at the second end
18-2. As the air flows into the aerosol carrier 14-2, it passes
across the activation surface of the fluid-transfer article. Heat
from the heater 24-2, which opposes the activation surface of the
fluid-transfer article, causes vaporization of aerosol precursor
material at the activation surface of the fluid-transfer article
and an aerosol is created in the air flowing over the activation
surface. Thus, through the application of heat in the region of the
activation surface of the fluid-transfer article, an aerosol is
released, or liberated, from the fluid-transfer article, and is
drawn from the material of the aerosol carrier unit by the air
flowing across the activation surface and is transported in the air
flow to via outlet conduits (not shown in FIG. 17) in the housing
of the aerosol carrier 14-2 to the second end 18-2. The direction
of air flow is illustrated by arrows in FIG. 17.
[0426] To achieve release of the captive aerosol from the
fluid-transfer article, the fluid-transfer article of the aerosol
carrier 14-2 is heated by the heater 24-2. As a user sucks or
inhales on second end 18-2 of the aerosol carrier 14-2, the aerosol
released from the fluid-transfer article and entrained in the air
flowing across the activation surface of the fluid-transfer article
is drawn through the outlet conduits (not shown) in the housing of
the aerosol carrier 14-2 towards the second end 18-2 and onwards
into the user's mouth.
[0427] Turning now to FIG. 18, a cross-sectional side view of the
aerosol delivery system 10-2 is schematically illustrated showing
the features described above in relation to FIG. 16 and FIG. 17 in
more detail. As can be seen, apparatus 12-2 comprises a housing
26-2, in which are located the receptacle 22-2 and heater 24-2. The
housing 26-2 also contains control circuitry (not shown) operative
by a user, or upon detection of air and/or vapor being drawn into
the device 12-2 through air-intake apertures 20-2, i.e., when the
user sucks or inhales. Additionally, the housing 26-2 comprises an
electrical energy supply 28-2, for example a battery. Optionally,
the battery comprises a rechargeable lithium-ion battery. The
housing 26-2 also comprises a coupling 30-2 for electrically (and
optionally mechanically) coupling the electrical energy supply 28-2
to control circuitry (not shown) for powering and controlling
operation of the heater 24-2.
[0428] Responsive to activation of the control circuitry of
apparatus 12-2, the heater 24-2 heats the fluid-transfer article
(not shown in FIG. 18) of aerosol carrier 14-2. This heating
process initiates (and, through continued operation, maintains)
release of vapor and/or an aerosol from the activation surface of
the fluid-transfer article. The vapor and/or aerosol formed as a
result of the heating process is entrained into a stream of air
being drawn across the activation surface of the fluid-transfer
article (as the user sucks or inhales). The stream of air with the
entrained vapor and/or aerosol passes through the aerosol carrier
14-2 via outlet conduits (not shown) and exits the aerosol carrier
14-2 at second end 18-2 for delivery to the user. This process is
briefly described above in relation to FIG. 17, where arrows
schematically denote the flow of the air stream into the device
12-2 and through the aerosol carrier 14-2, and the flow of the air
stream with the entrained vapor and/or aerosol through the aerosol
carrier cartridge 14-2.
[0429] FIGS. 19 to 21 schematically illustrate the aerosol carrier
14-2 in more detail (and, in FIGS. 20 and 21, features within the
receptacle in more detail). FIG. 19 illustrates an exterior of the
aerosol carrier 14-2, FIG. 20 illustrates internal components of
the aerosol carrier 14-2 in one optional configuration, and FIG. 21
illustrates internal components of the aerosol carrier 14-2 in
another optional configuration. FIG. 4 illustrates the exterior of
the aerosol carrier 14-2, which comprises housing 32-2 for housing
said fluid-transfer article (not shown) and at least one other
internal component. The particular housing 32-2 illustrated in FIG.
19 comprises a tubular member, which may be generally cylindrical
in form, and which is configured to be received within the
receptacle of the apparatus. First end 16-2 of the aerosol carrier
14-2 is for location to oppose the heater of the apparatus, and
second end 18-2 (and the region adjacent the second end 18-2) is
configured for insertion into a user's mouth.
[0430] FIG. 20 illustrates some internal components of the aerosol
carrier 14-2 and of the heater 24-2 of apparatus 12-2, in in one
embodiment of the disclosure.
[0431] As described above, the aerosol carrier 14-2 comprises a
fluid-transfer article 34-2. Optionally, there may be a conduction
element 36-2 (as shown in FIG. 20), being part of the heater 24-2.
In one or more arrangements, the aerosol carrier 14-2 is located
within the receptacle of the apparatus such that the activation
surface of the fluid-transfer article opposes the heater 24-2 of
the apparatus and receives heat directly from the heater 24-2 of
the apparatus. When aerosol carrier 14-2 is located within the
receptacle of the apparatus such that the activation surface of the
fluid-transfer article is located to oppose the heater of the
apparatus, the conduction element 36-2 is disposed between the rest
of the heater 24-2 and the activation surface 35-2 of the
fluid-transfer article. Heat may be transferred to the activation
surface 35-2 via conduction through conduction element 36-2 (i.e.,
application of heat to the activation surface is indirect).
[0432] Further components not shown in FIG. 20 comprise: an inlet
conduit, via which air can be drawn into the aerosol carrier 14-2;
an outlet conduit, via which an air stream entrained with aerosol
can be drawn from the aerosol carrier 14-2; a filter element; and a
reservoir for storing aerosol precursor material and for providing
the aerosol precursor material to the fluid-transfer article
34-2.
[0433] In FIG. 20, the aerosol carrier is shown as comprising the
fluid-transfer article 34-2 located within housing 32. The fluid
transfer article 34-2 comprises a first region 34a-2 holding an
aerosol precursor. In one or more arrangements, the first region of
34a of the fluid transfer article 34-2 comprises a reservoir for
holding the aerosol precursor. The first region 34a-2 can be the
sole reservoir of the aerosol carrier 14-2, or it can be arranged
in fluid communication with a separate reservoir, where aerosol
precursor is stored for supply to the first region 34a-2. As shown
in FIG. 20, the material forming the first region of 34a comprises
a porous structure, whose pore diameter size varies between one end
of the first region 34a-2 and another end of the first region
34a-2. In the illustrated example of FIG. 20, the pore diameter
size decreases from a first end remote from heater 24-2 (the upper
end is as shown in the figure) to a second end. Although the figure
illustrates the pore diameter size changing in a step-wise manner
(i.e., a first part with pores having a diameter of first size, and
a second part with pores having a diameter of second, smaller
size), the change in pore size in the first region 34a-2 may be
gradual rather than step-wise. This configuration of pores having a
decreasing diameter size can provide a wicking effect, which can
serve to draw fluid through the first region 34a-2, towards heater
24-2.
[0434] The fluid transfer article 34-2 also comprises a second
region 34b-2. Aerosol precursor is drawn from the first region of
34a to the second region 34b-2 by the wicking effect of the
material forming the first region of 34a. Thus, the first region
34a-2 is configured to transfer the aerosol precursor to the second
region 34b-2 of the article 34-2.
[0435] The second region 34b-2 itself comprises a porous structure
formed by a porous polymer material. It is then preferable that the
pore diameter size of the porous structure of the second region
34b-2 is smaller than the pore diameter size of the immediately
adjacent part of the first region 34a-2. As mentioned above, the
porous polymer material may be a sintered material. Particular
examples of material suitable for the fluid-transfer article
include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE);
Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone
(PES); and Ultra-High Molecular Weight Polyethylene. Other suitable
materials may comprise, for example, BioVyon.TM. (by Porvair
Filtration Group Ltd) and materials available from Porex.COPYRGT..
Further optionally, a substrate forming the fluid-transfer article
may comprise Polypropylene (PP) or Polyethylene Terephthalate
(PET).
[0436] In FIG. 20, the second region 34b-2 terminates in an
activation surface 35-2 which is spaced from the adjacent surface
of the conduction element 36-2 such that there is no contact
between the activation surface and the conduction element of the
heater anywhere along their facing extent. The conduction element
36-2 transfers heat to the activation surface 35-2, thereby
releasing aerosol precursor which has reached that activation
surface 35-2 through the porous polymer material of the second
region 34b-2. That vapor and/or a mixture of vapor and aerosol, may
then pass in to the air between the activation surface 35-2 and the
conduction element 36-2.
[0437] In the particular embodiment illustrated in FIG. 20, both
the activation surface 35-2 and the adjacent surface of conduction
element 36-2 which it faces are generally planar, such that both
surfaces are arranged substantially parallel to one another.
However, in other embodiments it is envisaged that either the
activation surface 35-2, or the facing surface of the conduction
element 36-2, or indeed both, may be non-planar. In arrangements in
which the activation surface 35-2 and the facing surface of the
conduction element 36-2 are both non-planar, the two surfaces may
have complimentary profiles such that they are substantially
equi-spaced apart across their entire extent.
[0438] FIG. 20 also illustrates an opening 38-2 in the housing
32-2, which opening 38-2 is in communication with the air-intake
apertures 20-2. A further opening 39-2 communicates with a duct
40-2 within the housing 32-2, which duct 40-2 communicates with the
second end 18-2.
[0439] There is thus a fluid-flow path for air (hereinafter
referred to as an air-flow pathway) between openings 38-2 and 39-2,
linking the apertures 20-2 and the second end 18-2 of the aerosol
carrier. When the user sucks or inhales, air is drawn along the
air-flow pathway, along the surface of the conduction element 36-2
facing the activation surface 35-2, between the conduction element
36-2 and the activation surface of the second region 34b-2.
[0440] One or more droplets of the aerosol precursor will be
released from the second region 34b-2 and heated, to release vapor
or a mixture of aerosol and vapor from the conduction element 36-2
into the air flowing in the air-flow pathway between the openings
38-2, 39-2. The vapor or mixture passes, as the user sucks and
inhales, to the second end 18-2. As noted above, the conduction
element 36-2 may be absent in some arrangements. In such
arrangements there will nevertheless still be no contact between
the activation surface and the heater anywhere along their facing
extent.
[0441] The conduction element 36-2, if present, may comprise a thin
film of thermally conductive material, such as, for example, a
metal foil (for example, aluminum, brass, copper, gold, steel,
silver, or an alloy comprising anyone of the foregoing together
with thermally conductive plastics and/or ceramics).
[0442] In the illustrative examples of FIG. 20, the first region
34a-2 of the fluid-transfer article 34-2 is located at an
"upstream" end of the fluid-transfer article 34-2 and the second
region 34b-2 is located at a downstream" end of the fluid-transfer
article 34-2. That is, aerosol precursor is wicked, or is drawn,
from the "upstream" end of the fluid-transfer article 34-2 to the
"downstream" end of the fluid-transfer article 34-2 (as denoted by
arrow A in FIG. 20).
[0443] As mentioned above, the conduction element 36-2 need not be
present. FIG. 21 illustrates an embodiment corresponding to that of
FIG. 20, but without such a conduction element 36-2. The
arrangement of FIG. 21 is otherwise similar to that of FIG. 20, and
corresponding parts are indicated by the same reference numerals.
In the arrangement of FIG. 21, therefore, the activation surface
35-2 of the fluid-transfer article 34-2 is arranged to as to be
facing, and spaced from adjacent surface of the heater 24-2 itself.
Such an arrangement means that there is no contact between the
activation surface and the heater anywhere along their facing
extent. Thus, although proximate, the activation surface and the
heater do not touch one another anywhere along their interface. The
heater 24-2 transfers heat to the activation surface 35-2, thereby
releasing aerosol precursor which has reached that activation
surface 35-2 through the porous polymer material of the second
region 34b-2 in the same manner as discussed above in connection
with the arrangement of FIG. 20 That vapor and/or a mixture of
vapor and aerosol, may then pass in to the air between the
activation surface 35-2 and the conduction element 36-2.
[0444] In the particular embodiment illustrated in FIG. 21, both
the activation surface 35-2 and the adjacent surface of heater 24-2
which it faces are generally planar, such that both surfaces are
arranged substantially parallel to one another. However, in other
embodiments it is envisaged that either the activation surface
35-2, or the facing surface of the heater 24-2, or indeed both, may
be non-planar. In arrangements in which the activation surface 35-2
and the facing surface of the heater 24-2 are both non-planar, the
two surfaces may have complimentary profiles such that they are
substantially equi-spaced apart across their entire extent.
[0445] In the arrangements shown in FIGS. 20 and 21, the apertures
38-2, 39-2 are on opposite sides of the housing 32-2. FIGS. 22 and
23 show an alternative configuration, in which the fluid-transfer
article is annular, and the second part 34b-2 is then in the form
of annular diaphragm. In FIGS. 22 and 23, the second part 34b-2 is
illustrated in a position corresponding to that shown in FIGS. 20
and 21, where it is spaced from the conduction element 36-2 such
that it makes no contact with the conduction element 36-2. This
enables the air flow in the apparatus to be illustrated. Thus,
FIGS. 22 and 23 illustrate an aerosol carrier 14-2 according to one
or more possible arrangements in more detail. FIG. 22 is a
cross-section side view illustration of the aerosol carrier 14-2
and FIG. 23 is a perspective cross-section side view illustration
of the aerosol carrier 14-2.
[0446] As can be seen from FIGS. 22 and 23, the aerosol carrier
14-2 is generally tubular in form. The aerosol carrier 14-2
comprises housing 32-2, which defines the external walls of the
aerosol carrier 14-2 and which defines therein a chamber in which
are disposed the fluid-transfer article 34-2 (adjacent the first
end 16-2 of the aerosol carrier 14-2) and internal walls defining
the fluid communication pathway 48-2. Fluid communication pathway
48-2 defines a fluid pathway for an outgoing air stream from the
channels 40-2 to the second end 18-2 of the aerosol carrier 14-2.
In the examples illustrated in FIGS. 22 and 23, the fluid-transfer
article 34-2 is an annular shaped element located around the fluid
communication pathway 48-2.
[0447] In walls of the housing 32-2, there are provided inlet
apertures 50-2 to provide a fluid communication pathway for an
incoming air stream to reach the fluid-transfer article 34-2, and
particularly the air-flow pathway defined between the activation
surface of the fluid-transfer article 34-2 and the conduction
element 36-2 (or between the activation surface and the 15
heater).
[0448] In the illustrated example of FIGS. 22 and 23, the aerosol
carrier 14-2 further comprises a filter element 52-2. The filter
element 52-2 is located across the fluid communication pathway 48-2
such that an outgoing air stream passing through the fluid
communication pathway 48-2 passes through the filter element
52-2.
[0449] With reference to FIG. 23, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18-2 of the aerosol carrier
14-2, if configured as a mouthpiece), air is drawn into the carrier
through inlet apertures 50-2 extending through walls in the housing
32-2 of the aerosol carrier 14-2.
[0450] An incoming airstream 42a-2 from a first side of the aerosol
carrier 14-2 is directed to a first side of the second part 34b-2
of the fluid-transfer article 34-2 (e.g., via a gas communication
pathway within the housing of the carrier). An incoming air stream
42b-2 from a second side of the aerosol carrier 14-2 is directed to
a second side of the second part 34a-2 of the fluid-transfer
article 34-2 (e.g., via a gas communication pathway within the
housing of the carrier). When the incoming air stream 42a-2 from
the first side of the aerosol carrier 14-2 reaches the first side
of the second part 34b-2, the incoming air stream 42a-2 from the
first side of the aerosol carrier 14-2 flows between the second
part 34b-2 and the conduction element 36-2 (or between the second
part 34b-2 and heater 24-2 if the conduction element is omitted).
Likewise, when the incoming air stream 42b-2 from the second side
of the aerosol carrier 14-2 reaches the second side of the second
part 34a-2, the incoming air stream 42b-2 from the second side of
the aerosol carrier 14-2 flows between the second part 34a-2 and
the conduction element 36-2 (or between the second part 34b-2 and
heater 24-2). The air streams from each side are denoted by dashed
lines 44a-2 and 44b-2 in FIG. 23 As these air streams 44a-2 and
44b-2 flow, aerosol precursor on the activation surface 35-2 or on
the conduction element 36-2 (or on the heater 24-2) is entrained in
air streams 44a-2 and 44b-2.
[0451] In use, the heater 24-2 of the apparatus 12-2 serves to
raise a temperature of the conduction element 36-2 to a sufficient
temperature to release, or liberate, captive substances (i.e., the
aerosol precursor) to form a vapor and/or aerosol, which is drawn
downstream. As the air streams 44a-2 and 44b-2 continue their
passages, more released aerosol precursor is entrained within the
air streams 44a-2 and 44b-2. When the air streams 44a-2 and 44b-2
entrained with aerosol precursor meet at a mouth of the outlet
fluid communication pathway 48-2, they enter the outlet fluid
communication pathway 48-2 and continue until they pass through
filter element 52-2 and exit outlet fluid communication pathway
48-2, either as a single outgoing air stream, or as separate
outgoing air streams 46-2 (as shown). The outgoing air streams 46-2
are directed to an outlet, from where it can be inhaled by the user
directly (if the second end 18-2 of the aerosol capsule 14-2 is
configured as a mouthpiece), or via a mouthpiece. The outgoing air
streams 46-2 entrained with aerosol precursor are directed to the
outlet (e.g., via a gas communication pathway within the housing of
the carrier).
[0452] FIG. 24 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10-2. In any
of the embodiments described above the second part 34b-2 may have a
thickness of less than 5 mm. In other embodiments it may have a
thickness of: less than 3.5 mm, less than 3 mm, less than 2.5 mm,
less than 2 mm, less than 1.9 mm, less than 1.8 mm, less than 1.7
mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm, less than
1.3 mm, less than 1.2 mm, less than 1.1 mm, less than 1 mm, less
than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than 0.6 mm,
less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less than 0.2
mm, or less than 0.1 mm.
[0453] As will be appreciated, in the arrangements described above,
the fluid-transfer article 34-2 is provided within a housing 32-2
of the aerosol carrier 14-2. In such arrangements, the housing of
the carrier 14-2 serves to protect the aerosol precursor-containing
fluid-transfer article 34-2, whilst also allowing the carrier 14-2
to be handled by a user without his/her fingers coming into contact
with the aerosol precursor liquid retained therein.
[0454] Third Mode: An Aerosol Generation Apparatus has a
Fluid-Transfer Article with a First Region which Holds an Aerosol
Precursor
[0455] Aspects and embodiments of the third mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the third mode will be
apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0456] In general outline, one or more embodiments of the third
mode in accordance with the present disclosure may provide a system
for aerosol delivery in which an aerosol carrier may be inserted
into a receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier. Another end, or another end portion, of the aerosol
carrier may protrude from the apparatus and can be inserted into
the mouth of a user for the inhalation of aerosol released from the
aerosol carrier cartridge during operation of the apparatus.
[0457] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
[0458] Referring now to FIG. 25, there is illustrated a perspective
view of an aerosol delivery system 10-3 comprising an aerosol
generation apparatus 12-3 operative to initiate and maintain
release of aerosol from a fluid-transfer article in an aerosol
carrier 14-3. In the arrangement of FIG. 25, the aerosol carrier
14-3 is shown with a first end 16-3 thereof and a portion of the
length of the aerosol carrier 14-3 located within a receptacle of
the apparatus 12-3. A remaining portion of the aerosol carrier 14-3
extends out of the receptacle. This remaining portion of the
aerosol carrier 14-3, terminating at a second end 18-3 of the
aerosol carrier, is configured for insertion into a user's mouth. A
vapor and/or aerosol is produced when a heater (not shown in FIG.
25) of the apparatus 12-3 heats a fluid-transfer article in the
aerosol carrier 14-3 to release a vapor and/or an aerosol, and this
can be delivered to the user, when the user sucks or inhales, via a
fluid passage in communication with an outlet of the aerosol
carrier 14-3 from the fluid-transfer article to the second end
18-3.
[0459] The device 12-3 also comprises air-intake apertures 20-3 in
the housing of the apparatus 12-3 to provide a passage for air to
be drawn into the interior of the apparatus 12-3 (when the user
sucks or inhales) for delivery to the first end 16-3 of the aerosol
carrier 14-3, so that the air can be drawn across an activation
surface of a fluid-transfer article located within a housing of the
aerosol carrier cartridge 14-3 during use. Optionally, these
apertures may be perforations in the housing of the apparatus
12-3.
[0460] A fluid-transfer article 34-3 (not shown in FIG. 25, but
described hereinafter with reference to FIGS. 29 to 32 is located
within a housing of the aerosol carrier 14-3. The fluid-transfer
article 34-3 contains an aerosol precursor material, which may
include at least one of: nicotine; a nicotine precursor material; a
nicotine compound; and one or more flavorings. The fluid-transfer
article 34-3 is located within the housing of the aerosol carrier
14-3 to allow air drawn into the aerosol carrier 14-3 at, or
proximal, the first end 16-3, and has first and second regions, as
will be described.
[0461] The first region of the fluid-transfer article 34-3 may
comprise a substrate of porous material where pores of the porous
material hold, contain, carry, or bear the aerosol precursor
material. In particular, the porous material of the fluid-transfer
article may be a porous polymer material such as, for example, a
sintered material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET). All such
materials may be described as heat resistant polymeric wicking
material in the context of the present disclosure.
[0462] Alternatively, in some embodiments it is envisaged that the
first region of the fluid-transfer article 34-3 may take the form
of a simple tank having a cavity defining a hollow reservoir to
hold the aerosol precursor.
[0463] The aerosol carrier 14-3 is removable from the apparatus
12-3 so that it may be disposed of when expired. After removal of a
used aerosol carrier 14-3, a replacement aerosol carrier 14-3 can
be inserted into the apparatus 12-3 to replace the used aerosol
carrier 14-3.
[0464] FIG. 26 is a cross-sectional side view illustration of a
part of apparatus 12-3 of the aerosol delivery system 10. The
apparatus 12-3 comprises a receptacle 22-3 in which is located a
portion of the aerosol carrier 14-3. In one or more optional
arrangements, the receptacle 22-3 may enclose the aerosol carrier
14-3. The apparatus 12-3 also comprises a heater 24-3, which is
proximate but spaced from an activation surface of the
fluid-transfer article 34-3 when an aerosol carrier 14-3 is located
within the receptacle 22-3. Optional configurations of the heater
24-3 will be discussed later.
[0465] Air flows into the apparatus 12-3 (in particular, into a
closed end of the receptacle 22-3) via air-intake apertures 20-3.
From the closed end of the receptacle 22-3, the air is drawn into
the aerosol carrier 14-3 (under the action of the user inhaling or
sucking on the second end 18-3) and expelled at the second end
18-3. As the air flows into the aerosol carrier 14-3, it passes
across the activation surface. Heat from the heater 24-3 heats the
activation surface of the fluid-transfer article 34-3, causing
vaporization of aerosol precursor material at the activation
surface of the fluid-transfer article 34-3 and an aerosol is
created in the air flowing over the activation surface. Thus,
through the application of heat to the activation surface, an
aerosol is released, or liberated, from the fluid-transfer article,
and is drawn from the material of the aerosol carrier unit by the
air flowing across the activation surface and is transported in the
air flow to via outlet conduits (not shown in FIG. 26) in the
housing of the aerosol carrier 14-3 to the second end 18-3. The
direction of air flow is illustrated by arrows in FIG. 26.
[0466] To achieve release of the captive aerosol from the
fluid-transfer article, the activation surface of the
fluid-transfer article 34-3 is heated by the heater 24-3. As a user
sucks or inhales on second end 18-3 of the aerosol carrier 14-3,
the aerosol released from the fluid-transfer article and entrained
in the air flowing across the activation surface is drawn through
the outlet conduits (not shown) in the housing of the aerosol
carrier 14-3 towards the second end 18-3 and onwards into the
user's mouth.
[0467] Turning now to FIG. 27, a cross-sectional side view of the
aerosol delivery system 10-3 is schematically illustrated showing
the features described above in relation to FIGS. 25 and 26 in more
detail. As can be seen, apparatus 12-3 comprises a housing 26-3, in
which is located the receptacle 22-3. The housing 26-3 also
contains control circuitry (not shown) operative by a user, or upon
detection of air and/or vapor being drawn into the device 12-3
through air-intake apertures 20-3, i.e., when the user sucks or
inhales. Additionally, the housing 26-3 comprises an electrical
energy supply 28-3, for example a battery. Optionally, the battery
comprises a rechargeable lithium-ion battery. The housing 26-3 also
comprises a coupling 30-3 for electrically (and optionally
mechanically) coupling the electrical energy supply 28-3 to control
circuitry (not shown) for powering and controlling operation of the
heater 24-3.
[0468] Responsive to activation of the control circuitry of
apparatus 12-3, the heater 24-3 heats the activation surface of the
fluid-transfer article 34-3 (not shown in FIG. 27). This heating
process initiates (and, through continued operation, maintains)
release of vapor and/or an aerosol from the activation surface of
the fluid-transfer article 34-3. The vapor and/or aerosol formed as
a result of the heating process is entrained into a stream of air
being drawn across the activation surface of the fluid-transfer
article 34-3 (as the user sucks or inhales). The stream of air with
the entrained vapor and/or aerosol passes through the aerosol
carrier 14-3 via outlet conduits (not shown) and exits the aerosol
carrier 14-3 at second end 18-3 for delivery to the user. This
process is briefly described above in relation to FIG. 26, where
arrows schematically denote the flow of the air stream into the
device 12-3 and through the aerosol carrier 14-3, and the flow of
the air stream with the entrained vapor and/or aerosol through the
aerosol carrier cartridge 14-3.
[0469] FIGS. 28 to 30 schematically illustrate the aerosol carrier
14-3 in more detail (and, in FIGS. 29 and 30, features within the
receptacle in more detail). FIG. 28 illustrates an exterior of the
aerosol carrier 14-3, FIG. 29 illustrates internal components of
the aerosol carrier 14-3 in one optional configuration, and FIG. 30
illustrates internal components of the aerosol carrier 14-3 in
another optional configuration.
[0470] FIG. 28 illustrates the exterior of the aerosol carrier
14-3, which comprises housing 32-3 for housing said fluid-transfer
article (not shown). The particular housing 32-3 illustrated in
FIG. 28 comprises a tubular member, which may be generally
cylindrical in form, and which is configured to be received within
the receptacle of the apparatus. First end 16-3 of the aerosol
carrier 14-3 is for location to oppose the heater of the apparatus,
and second end 18-3 (and the region adjacent the second end 18-3)
is configured for insertion into a user's mouth.
[0471] FIG. 29 illustrates some internal components of the aerosol
carrier 14-3 and of the heater 24-3 of apparatus 12-3, in one
embodiment of the disclosure.
[0472] As described above, the aerosol carrier 14-3 comprises a
fluid-transfer element 34-3. At least part of the fluid-transfer
article 34-3 may be removable from the housing 32-3, to enable it
to be replaced. The fluid-transfer article 34-3 acts as a reservoir
for aerosol precursor and that aerosol precursor will be consumed
as the apparatus is used. Once sufficient aerosol precursor has
been consumed, the aerosol precursor will need to be replaced. It
may then be easiest to replace it by replacing the fluid-transfer
article 34-3, rather than trying to re-fill the fluid-transfer
article 34-3 with aerosol precursor while it is in the housing
32-3.
[0473] In the illustrated embodiments, the fluid-transfer article
34-3 has a first region 35-3 formed by layers 35a-3 and 35b-3, and
a second region 36-3. That second region 36-3 has a first part
being an upper layer 36a-3 which is formed by a plate with a
plurality of holes 37-3 therein, and a second part being a lower
layer formed by a second plate 36b-3 made of a porous material
which allows aerosol precursor to pass therethrough. In the
arrangement of FIG. 29, the plate 36a-3 with holes 37-3 therein is
in contact with the first region 35-3 of the fluid-transfer article
34-3, so that aerosol precursor may pass from that first region
35-3 directly into the holes 37-3, and through those holes to the
second plate 36b-3.
[0474] Since the second plate 36b-3 is porous, the aerosol
precursor will pass to the surface of the plate 36b-3 remote from
the first region 35-3 of the fluid-transfer article 34-3, which
surface acts as an activation surface 41-3 of the fluid-transfer
article 34-3. A heater 24-3 is mounted so as to be proximate but
spaced from the activation surface 41-3. When the heater 24-3 is
activated, the heat which it generates will be transferred to the
activation surface 41-3. The spacing between the activation surface
41-3 and the heater 24-3 is preferably between 0.05 mm and 0.5 mm.
The spacing is chosen so as to ensure efficient heating of the
activation surface 41-3 by the heater 24-3, but allow satisfactory
air flow between the activation surface 41-3 and the heater
24-3.
[0475] Further components not shown in FIG. 29 comprise: an inlet
conduit, via which air can be drawn into the aerosol carrier 14-3;
an outlet conduit, via which an air stream entrained with aerosol
can be drawn from the aerosol carrier 14-3; a filter element; and a
reservoir for storing aerosol precursor material and for providing
the aerosol precursor material to the fluid-transfer article
34-3.
[0476] In FIG. 29, the aerosol carrier is shown as comprising the
fluid-transfer article 34-3 located within housing 32-3. The fluid
transfer article 34-3 comprises a first region 35-3 holding an
aerosol precursor. In one or more arrangements, the fluid transfer
article 34-3 comprises a reservoir for holding the aerosol
precursor. The first region 35-3 can be the sole reservoir of the
aerosol carrier 14-3, or it can be arranged in fluid communication
with a separate reservoir, where aerosol precursor is stored for
supply to the first region 35-3. As shown in FIG. 29, the first
region 35-3 has a first layer 35a-3 and a second layer 35b-3. The
material forming the first layer 35a-3 of the first region 35-3
comprises a porous structure, whose pore diameter size varies
between one end of the first layer 35a-3 and another end of the
first layer 35a-3. The pore diameter size may increase from a first
end remote from heater 24-3 (the upper end is as shown in the
figure) to a second end. The pore diameter size may change in a
step-wise manner (i.e., a first part with pores having a diameter
of first size, and a second part with pores having a diameter of
second, smaller size), or the change in pore size in the first
layer 35a-3 may be gradual rather than step-wise. This
configuration of pores having a decreasing diameter size can
provide a wicking effect, which can serve to draw fluid through the
first layer 35a-3, towards heater 24-3.
[0477] The first region 35-3 of the fluid transfer article 34-3 may
also comprise a second layer 35b-3. Aerosol precursor is drawn from
the first layer 35a-3 to the second layer 35b-3 by the wicking
effect of the material forming the first layer 35a-3. Thus, the
first layer 35a-3 is configured to transfer the aerosol precursor
to the second layer 35b-3 of the first region 35-3 of the
fluid-transfer article 34-3.
[0478] The second layer 35b-3 itself may comprise a porous
structure formed by a porous polymer material. It is then
preferable that the pore diameter size of the porous structure of
the second layer 35b-3 is smaller than the pore diameter size of
the immediately adjacent part of the first layer 35a-3. As
mentioned above, the porous polymer material may be a sintered
material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET).
[0479] However, as mentioned previously, in some embodiments it is
envisaged that the first region 35-3 of the fluid-transfer article
need not be of porous polymer material as described above. Instead,
the first region 35-3 of the fluid-transfer article 34-3 may take
the form of a simple tank having a cavity defining a hollow
reservoir to hold the aerosol precursor. In such embodiments it is
proposed that the plate 36a-3 with holes 37-3 therein will extend
across the bottom of the tank so that aerosol precursor held in the
tank will impinge directly on the plate 36a-3 and pass directly
from the tank defining the first region 35-3 of the fluid-transfer
article 34-3 into the holes 37-3 of the second region 36-3 of the
fluid-transfer article.
[0480] As discussed above, the heater 24-3 transfers heat to the
activation surface 41-3, thereby releasing aerosol precursor which
has reached that activation surface 41-3 from the porous polymer
material (or hollow reservoir) of the first region 35-3, through
the second region 36-3. That vapor and/or a mixture of vapor and
aerosol, may then pass into the air adjacent the activation surface
41-3, between the heater 24-3 and the activation surface.
[0481] FIG. 29 also illustrates an opening 38-3, which opening 38-3
is in communication with the air-intake apertures 20-3. A further
opening 39-3 communicates with a duct 40-3 within the housing 32-3,
which duct 40-3 communicates with the second end 18-3.
[0482] There is thus a fluid-flow path for air (referred to as an
air-flow pathway) between openings 38-3 and 39, linking the
apertures 20-3 and the second end 18-3 of the aerosol carrier. When
the user sucks or inhales, air is drawn along the air-flow pathway,
along the activation surface 41-3. The heater 24-3 forms a lower
surface of the air-flow pathway. As mentioned above, the spacing
between the activation surface 41-3 and the heater 24-3 needs to be
small enough to allow good heat transfer from the heater 24-3 to
the activation surface 41-3, but large enough to allow sufficient
air flow along the air-flow pathway. Thus, the spacing between the
activation surface and the heater is preferably 0.5 mm to 0.05
mm.
[0483] One or more droplets of the aerosol precursor will be
released from the second plate 36b-3 and heated, to release vapor
or a mixture of aerosol and vapor into the air flowing in the
air-flow pathway between the openings 38-3, 39-3. The vapor or
mixture passes, as the user sucks and inhales, to the second end
18-3.
[0484] As mentioned above, the second region 36-3 of the
fluid-transfer article 34-3 comprises a first plate 36a-3 and a
second plate 36b-3. The first plate 36a-3 may be a molded polymer
disc so that is then easy to form the holes 37-3 therein by molding
the holes 37-3 when the plate 36a-3 is itself molded. The holes
37-3 are sufficiently large that they do not act as a capillary,
but instead define non-capillary spaces in the second region 36-3.
Hence, aerosol precursor is able to pass from the first region 35-3
of the fluid-transfer article to the second region 36-3 in a
non-capillary manner, into the holes 37-3, and then pass through
the second plate 36b-3 to the heater or heaters 24-3. The holes
37-3 may be relatively large, so that they fill with aerosol
precursor when the apparatus is in use.
[0485] The second plate 36b-3 is made of a porous material which is
more heat-resistant than the material of the plate 36a-3, as it is
acted on by the heater 24-3. It may be fibrous, made from e.g.,
ceramic fiber, glass fiber or carbon fiber. Alternatively, it may
be formed from a high-temperature porous material such as porous
glass or porous ceramic. Another possibility is that the second
plate 36b-3 may be of a porous polymer material, such as the
materials described previously with reference to the layers 35a-3
and 35b-3 of the first region 35-3, provided that the polymer
material is sufficiently resistant to the high temperatures to
which it will be subject due to the heater 24-3.
[0486] It is thought that the flow of air between openings 38-3 and
39-3 along the activation surface 41-3 and past the heater 24-3
will have the effect of creating the lower air pressure adjacent
the activation surface 41-3 which will tend to draw liquid through
the porous second plate 36b-3 to the activation surface 41-3. Thus,
the transfer of aerosol precursor from the fluid-transfer article
34-3 is facilitated.
[0487] As mentioned above, the fluid-transfer article 34-3, formed
by the first and second regions 35-3 and 36-3 and any further
reservoir of aerosol precursor, forms the consumable part of the
apparatus, in the sense that it can readily be replaced to enable
the aerosol precursor to be replaced once it is consumed. The
heater 24-3 is not part of the consumable elements. Thus, the
housing 32-3 containing the fluid-transfer article 34-3 may be
separable from a housing 43-3 supporting the heater 24-3 e.g.,
along the line B-B in FIG. 29 The openings 38-3 and 39-3 are formed
in the further housing 43-3. The further housing 43-3 may be
integral with the housing 26-3 containing the electrical energy
supply 28-3. The heater 24-3 must be separable from the
fluid-transfer article 34-3 to allow removal of the housing 32-3
from the further housing 43-3 when the fluid-transfer article 34-3
has become depleted. The line of separation of the housing 32-3 and
further housing 43-3 may therefore correspond to the plane of the
activation surface 41-3 (along the line B-B), or any other line
running between the activation surface 41-3 and the heater
24-3.
[0488] In the arrangement of FIG. 29, there is an optional
conduction element 25-3, being part of the heater 24-3, facing the
activation surface 41-3. Heat will be transferred to the activation
surface 41-3 via conduction through the conduction element 25-3, so
that the application of heat to the activation surface is indirect.
The air-flow pathway is thus between the conduction element 25-3 of
the heater 24-3 and the activation surface 41-3.
[0489] The conduction element 25-3, if present, may comprise a thin
film of thermally conductive material, such as, for example, a
metal foil (for example, aluminum, brass, copper, gold, steel,
silver, or an alloy comprising anyone of the foregoing together
with thermally conductive plastics and/or ceramics).
[0490] In the illustrative examples of FIG. 29, the first layer
35a-3 of the first region 35-3 of the fluid-transfer article 34-3
is located at an "upstream" end of the fluid-transfer article 34-3
and the second plate 35b-3 of the second region 35b-3 is located at
a downstream" end of the fluid-transfer article 34-3. That is,
aerosol precursor is wicked, or is drawn, from the "upstream" end
of the fluid-transfer article 34-3 to the "downstream" end of the
fluid-transfer article 34-3 (as denoted by arrow A in FIG. 29).
[0491] As mentioned above, the conduction element 25-3 is optional.
FIG. 30 illustrates an arrangement in which that conduction element
36-3 is omitted, from the body of the heater adjacent to the
activation surface 41-3. Other components of FIG. 30 which are the
same as components of FIG. 29 are indicated by the same reference
numerals.
[0492] In the arrangements shown in FIGS. 29 and 30, the apertures
38-3, 39 are on opposite sides of the housing 32-3. FIGS. 31 and 32
shows an alternative configuration, in which the fluid-transfer
article is annular, and both the first region 35-3 and the second
region 36-3 are then in the form of annuli. In FIGS. 32 and 33, the
structure of the fluid-transfer article 34-3, including the first
region 35-3 and the second region 36-3 may correspond generally to
that shown in FIG. 29 The internal structure of the first and
second regions 35-3 and 36-3 may be the same as in FIG. 29, but are
not illustrated in detail in FIGS. 31 and 32 for simplicity.
[0493] The heater 24-3 also may be formed as in the arrangement of
FIG. 29 or FIG. 30 The air flow in the apparatus is discussed in
more detail below. Thus, FIGS. 31 and 32 illustrate an aerosol
carrier 14-3 according to one or more possible arrangements in more
detail. FIG. 31 is a cross-section side view illustration of the
aerosol carrier 14-3 and FIG. 32 is a perspective cross-section
side view illustration of the aerosol carrier 14-3.
[0494] As can be seen from FIGS. 31 and 32, the aerosol carrier
14-3 is generally tubular in form. The aerosol carrier 14-3
comprises housing 32-3, which defines the external walls of the
aerosol carrier 14-3 and which defines therein a chamber in which
are disposed the fluid-transfer article 34-3 (adjacent the first
end 16-3 of the aerosol carrier 14-3) and internal walls defining
the fluid communication pathway 48-3. Fluid communication pathway
48-3 defines a fluid pathway for an outgoing air stream from the
channels 40-3 to the second end 18-3 of the aerosol carrier 14-3.
In the examples illustrated in FIGS. 31 and 32, the fluid-transfer
article 34-3 is an annular shaped element located around the fluid
communication pathway 48-3. The housing 32-3 containing the
fluid-transfer article 34-3 is separable from the housing 43-3
supporting the heater 24-3.
[0495] In walls of the housing 43-3, there are provided inlet
apertures 50-3 to provide a fluid communication pathway for an
incoming air stream to reach the activation surface 41-3 of the
second region 36-3 of the fluid-transfer article 34-3.
[0496] In the illustrated example of FIGS. 31 and 32, the aerosol
carrier 14-3 further comprises a filter element 52-3. The filter
element 52-3 is located across the fluid communication pathway 48-3
such that an outgoing air stream passing through the fluid
communication pathway 48-3 passes through the filter element
52-3.
[0497] With reference to FIG. 32, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18-3 of the aerosol carrier
14-3, if configured as a mouthpiece), air is drawn into the carrier
through inlet apertures 50-3 extending through walls in the housing
32-3 of the aerosol carrier 14-3.
[0498] An incoming airstream 42a-3 from a first side of the aerosol
carrier 14-3 is directed to a first side of the second region 36-3
(e.g., via a gas communication pathway within the housing of the
carrier). An incoming air stream 42b-3 from a second side of the
aerosol carrier 14-3 is directed to a second side of the second
region 36-3 (e.g., via a gas communication pathway within the
housing of the carrier). When the incoming air stream 42a-3 from
the first side of the aerosol carrier 14-3 reaches the first side
of the second region 36-3, the incoming air stream 42a-3 from the
first side of the aerosol carrier 14-3 flows along the activation
surface 41-3 of the second region 36-3. Likewise, when the incoming
air stream 42b-3 from the second side of the aerosol carrier 14-3
reaches the second side of the second region 36-3, the incoming air
stream 42b-3 from the second side of the aerosol carrier 14-3 flows
along the activation surface 41-3 of the second region 36-3. The
air streams from each side are denoted by dashed lines 44a-3 and
44b-3 in FIG. 32 As these air streams 44a-3 and 44b-3 flow, aerosol
precursor on the activation surface 41-3 of the second region 36-3
is entrained in air streams 44a-3 and 44b-3.
[0499] In use, the heater or heaters 24-3 of the apparatus 12-3
raise a temperature of the second plate 36b-3 of the second region
36-3 to a sufficient temperature to release, or liberate, captive
substances (i.e., the aerosol precursor) to form a vapor and/or
aerosol, which is drawn downstream. As the air streams 44a-3 and
44b-3 continue their passages, more released aerosol precursor is
entrained within the air streams 44a-3 and 44b-3. When the air
streams 44a-3 and 44b-3 entrained with aerosol precursor meet at a
mouth of the outlet fluid communication pathway 48-3, they enter
the outlet fluid communication pathway 48-3 and continue until they
pass through filter element 52-3 and exit outlet fluid
communication pathway 48-3, either as a single outgoing air stream,
or as separate outgoing air streams 46-3 (as shown). The outgoing
air streams 46-3 are directed to an outlet, from where it can be
inhaled by the user directly (if the second end 18-3 of the aerosol
capsule 14-3 is configured as a mouthpiece), or via a mouthpiece.
The outgoing air streams 46-3 entrained with aerosol precursor are
directed to the outlet (e.g., via a gas communication pathway
within the housing of the carrier).
[0500] FIG. 33 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10-3.
[0501] As will be appreciated, in the arrangements described above,
the fluid-transfer article 34-3 is provided within a housing 32-3
of the aerosol carrier 14-3. In such arrangements, the housing of
the carrier 14-3 serves to protect the aerosol precursor-containing
fluid-transfer article 34-3, whilst also allowing the carrier 14-3
to be handled by a user without his/her fingers coming into contact
with the aerosol precursor liquid retained therein.
[0502] In any of the embodiments described above the second plate
36b-3 of the second region 36-3 may have a thickness of less than 5
mm. In other embodiments it may have a thickness of: less than 3.5
mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9
mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than
1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less
than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm,
less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4
mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.
[0503] Fourth Mode: An Aerosol Generation Apparatus has a
Fluid-Transfer Article which Holds Aerosol Precursor and which
Transfers that Aerosol Precursor to a Transfer Surface
[0504] Aspects and embodiments of the fourth mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the fourth mode will be
apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0505] In general outline, one or more embodiments of the fourth
mode in accordance with the present disclosure may provide a system
for aerosol delivery in which an aerosol carrier may be inserted
into a receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier. Another end, or another end portion, of the aerosol
carrier may protrude from the apparatus and can be inserted into
the mouth of a user for the inhalation of aerosol released from the
aerosol carrier cartridge during operation of the apparatus.
[0506] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
[0507] Referring now to FIG. 34, there is illustrated a perspective
view of an aerosol delivery system 10-4 comprising an aerosol
generation apparatus 12-4 operative to initiate and maintain
release of aerosol from a fluid-transfer article in an aerosol
carrier 14-4. In the arrangement of FIG. 34, the aerosol carrier
14-4 is shown with a first end 16-4 thereof and a portion of the
length of the aerosol carrier 14-4 located within a receptacle of
the apparatus 12-4. A remaining portion of the aerosol carrier 14-4
extends out of the receptacle. This remaining portion of the
aerosol carrier 14-4, terminating at a second end 18-4 of the
aerosol carrier, is configured for insertion into a user's mouth. A
vapor and/or aerosol is produced when a heater (not shown in FIG.
34) of the apparatus 12-4 heats a fluid-transfer article in the
aerosol carrier 14-4 to release a vapor and/or an aerosol, and this
can be delivered to the user, when the user sucks or inhales, via a
fluid passage in communication with an outlet of the aerosol
carrier 14-4 from the fluid-transfer article to the second end
18-4.
[0508] The device 12-4 also comprises air-intake apertures 20-4 in
the housing of the apparatus 12-4 to provide a passage for air to
be drawn into the interior of the apparatus 12-4 (when the user
sucks or inhales) for delivery to a heater associated with the
first end 16-4 of the aerosol carrier 14-4, so that the air can be
drawn across an activation surface of the heater during use.
Optionally, these apertures may be perforations in the housing of
the apparatus 12-4.
[0509] A fluid-transfer article (not shown in FIG. 34, but
described hereinafter with reference to FIGS. 38 to 42 is located
within a housing of the aerosol carrier 14-4. The fluid-transfer
article contains an aerosol precursor material, which may include
at least one of: nicotine; a nicotine precursor material; a
nicotine compound; and one or more flavorings. As air passes across
the activation surface of the heater, an aerosol may be entrained
in the air stream, e.g., via diffusion to the air stream and/or via
vaporization of the aerosol precursor material and release from the
heater under heating.
[0510] The substrate forming the fluid-transfer article 34-4
comprises a porous material where pores of the porous material
hold, contain, carry, or bear the aerosol precursor material. In
particular, the porous material of the fluid-transfer article is a
porous polymer material such as, for example, a sintered material.
Particular examples of material suitable for the fluid-transfer
article include: Polyetherimide (PEI); Polytetrafluoroethylene
(PTFE); Polyether ether ketone (PEEK); Polyimide (PI);
Polyethersulphone (PES); and Ultra-High Molecular Weight
Polyethylene. Other suitable materials may comprise, for example,
BioVyon.TM. (by Porvair Filtration Group Ltd) and materials
available from Porex.COPYRGT.. Further optionally, a substrate
forming the fluid-transfer article may comprise Polypropylene (PP)
or Polyethylene Terephthalate (PET). All such materials may be
described as heat resistant polymeric wicking material in the
context of the present disclosure.
[0511] The aerosol carrier 14-4 is removable from the apparatus
12-4 so that it may be disposed of when expired. After removal of a
used aerosol carrier 14-4, a replacement aerosol carrier 14-4 can
be inserted into the apparatus 12-4 to replace the used aerosol
carrier 14-4.
[0512] FIG. 35 is a cross-sectional side view illustration of a
part of apparatus 12-4 of the aerosol delivery system 10. The
apparatus 12-4 comprises a receptacle 22-4 in which is located a
portion of the aerosol carrier 14-4. In one or more optional
arrangements, the receptacle 22-4 may enclose the aerosol carrier
14-4. The apparatus 12-4 also comprises a heater 24-4, which may
contact a transfer surface of the fluid-transfer article (not shown
in FIG. 35) of the aerosol carrier 14-4 when an aerosol carrier
14-4 is located within the receptacle 22-4. Optional configurations
of the heater 24-4 will be discussed later.
[0513] Air flows into the apparatus 12-4 (in particular, into a
closed end of the receptacle 22-4) via air-intake apertures 20-4.
From the closed end of the receptacle 22-4, the air is drawn into
the aerosol carrier 14-4 (under the action of the user inhaling or
sucking on the second end 18-4) and expelled at the second end
18-4. As the air flows towards the aerosol carrier 14-4, it passes
across the activation surface of the heater. Heat from the heating
elements of the heater 24-4 causes vaporization of aerosol
precursor material at the activation surface of the heater and an
aerosol is created in the air flowing over the activation surface.
Thus, through the application of heat in the region of the
activation surface an aerosol is released, or liberated and is
drawn from the material of the aerosol carrier unit by the air
flowing across the activation surface and is transported in the air
flow to via outlet conduits (not shown in FIG. 35) in the housing
of the aerosol carrier 14-4 to the second end 18-4. The direction
of air flow is illustrated by arrows in FIG. 35.
[0514] As a user sucks or inhales on second end 18-4 of the aerosol
carrier 14-4, the is aerosol released from the heater and entrained
in the air flowing across the activation surface of the heater is
drawn through the outlet conduits (not shown) in the housing of the
aerosol carrier 14-4 towards the second end 18-4 and onwards into
the user's mouth.
[0515] Turning now to FIG. 36, a cross-sectional side view of the
aerosol delivery system 10-4 is schematically illustrated showing
the features described above in relation to FIGS. 34 and 35 in more
detail. As can be seen, apparatus 12-4 comprises a housing 26-4, in
which are located the receptacle 22-4 and heater 24-4. The housing
26-4 also contains control circuitry (not shown) operative by a
user, or upon detection of air and/or vapor being drawn into the
device 12-4 through air-intake apertures 20-4, i.e., when the user
sucks or inhales. Additionally, the housing 26-4 comprises an
electrical energy supply 28-4, for example a battery. Optionally,
the battery comprises a rechargeable lithium-ion battery. The
housing 26-4 also comprises a coupling 30-4 for electrically (and
optionally mechanically) coupling the electrical energy supply 28-4
to control circuitry (not shown) for powering and controlling
operation of the heater 24-4.
[0516] Responsive to activation of the control circuitry of
apparatus 12-4, the heating elements of the heater 24-4 cause a
heating process to be initiated which causes (and, through
continued operation, maintains) release of vapor and/or an aerosol
from the activation surface of the heater. The vapor and/or aerosol
formed as a result of the heating process is entrained into a
stream of air being drawn across the activation surface of the
heater (as the user sucks or inhales). The stream of air with the
entrained vapor and/or aerosol passes through the aerosol carrier
14-4 via outlet conduits (not shown) and exits the aerosol carrier
14-4 at second end 18-4 for delivery to the user. This process is
briefly described above in relation to FIG. 35, where arrows
schematically denote the flow of the air stream into the device
12-4 and through the aerosol carrier 14-4, and the flow of the air
stream with the entrained vapor and/or aerosol through the aerosol
carrier cartridge 14-4.
[0517] FIGS. 37 to 39 schematically illustrate the aerosol carrier
14-4 in more detail (and, in FIGS. 38, 39 and 40, features within
the receptacle in more detail). FIG. 37 illustrates an exterior of
the aerosol carrier 14-4, FIG. 38 illustrates internal components
of the aerosol carrier 14-4 in one optional configuration, and
FIGS. 39 and 40 illustrate internal components of the aerosol
carrier 14-4 in other optional configurations.
[0518] FIG. 37 illustrates the exterior of the aerosol carrier
14-4, which comprises housing 32-4 for housing said fluid-transfer
article (not shown). The particular housing 32-4 illustrated in
FIG. 37 comprises a tubular member, which may be generally
cylindrical in form, and which is configured to be received within
the receptacle of the apparatus. First end 16-4 of the aerosol
carrier 14-4 is for location to oppose the heater of the apparatus,
and second end 18-4 (and the region adjacent the second end 18-4)
is configured for insertion into a user's mouth.
[0519] FIG. 38 illustrates some internal components of the aerosol
carrier 14-4 and of the heater 24-4 of apparatus 12-4, in one
embodiment of the disclosure.
[0520] As described above, the aerosol carrier 14-4 comprises a
fluid-transfer element 34-4. The fluid-transfer article 34-4 may be
removable from the housing 32-4, to enable it to be replaced. The
fluid-transfer article 34-4 acts as a reservoir for aerosol
precursor and that aerosol precursor will be consumed as the
apparatus is used. Once sufficient aerosol precursor has been
consumed, the aerosol precursor will need to be replaced. It may
then be easiest to replace it by replacing the fluid-transfer
article 34-4, rather than trying to re-fill the fluid-transfer
article 34-4 with aerosol precursor while it is in the housing
32-4.
[0521] Adjacent to, but separable from, the fluid-transfer article
34-4 is the heater 24-4, which has an element 23-4 of a porous
material which allows aerosol precursor to pass therethrough. In
the arrangement of FIG. 38 the porous element 23-4 of the heater
24-4 is in contact with transfer surface 35-4 of the fluid-transfer
article 34-4, so that aerosol precursor may pass from that transfer
surface 35-4 directly into the porous element 23-4 of the heater
24-4.
[0522] Since the element 23-4 is porous, the aerosol precursor will
pass to the surface of the element 23-4 remote from the
fluid-transfer article 34-4, which surface will be referred to as
an activation surface 41-4. Heating elements 25-4 of the heater
24-4 are mounted on the activation surface 41-4. When the heating
elements 25-4 are activated, the heat which they generate will be
transferred to the activation surface 41-4.
[0523] Further components not shown in FIG. 38 comprise: an inlet
conduit, via which air can be drawn into the aerosol carrier 14-4;
an outlet conduit, via which an air stream entrained with aerosol
can be drawn from the aerosol carrier 14-4; a filter element; and a
reservoir for storing aerosol precursor material and for providing
the aerosol precursor material to the fluid-transfer article
34-4.
[0524] In FIG. 38, the aerosol carrier is shown as comprising the
fluid-transfer article 34-4 located within housing 32-4. The fluid
transfer article 34-4 comprises a first region 34a-4 holding an
aerosol precursor. In one or more arrangements, the first region of
34a of the fluid transfer article 34-4 comprises a reservoir for
holding the aerosol precursor. The first region 34a-4 can be the
sole reservoir of the aerosol carrier 14-4, or it can be arranged
in fluid communication with a separate reservoir, where aerosol
precursor is stored for supply to the first region 34a-4. The
material forming the first region of 34a comprises a porous
structure, whose pore diameter size may vary between one end of the
first region 34a-4 and another end of the first region 34a-4. For
example, the pore diameter size may increase from a first end
remote from heater 24-4 (the upper end is as shown in the figure)
to a second end. The pore diameter size may change in a step-wise
manner (i.e., a first part with pores having a diameter of first
size, and a second part with pores having a diameter of second,
smaller size), or the change in pore size in the first region 34a-4
may be gradual rather than step-wise. This configuration of pores
having a decreasing diameter size can provide a wicking effect,
which can serve to draw fluid through the first region 34a-4,
towards heater 24-4.
[0525] The fluid transfer article 34-4 also comprises a second
region 34b-4. Aerosol precursor is drawn from the first region of
34a to the second region 34b-4 by the wicking effect of the
material forming the first region of 34a. Thus, the first region
34a-4 is configured to transfer the aerosol precursor to the second
region 34b-4 of the article 34-4.
[0526] The second region 34b-4 itself comprises a porous structure
formed by a porous polymer material. It is then preferable that the
pore diameter size of the porous structure of the second region
34b-4 is smaller than the pore diameter size of the immediately
adjacent part of the first region 34a-4. As mentioned above, the
porous polymer material may be a sintered material. Particular
examples of material suitable for the fluid-transfer article
include: Polyetherimide (PEI); Polytetrafluoroethylene (PTFE);
Polyether ether ketone (PEEK); Polyimide (PI); Polyethersulphone
(PES); and Ultra-High Molecular Weight Polyethylene. Other suitable
materials may comprise, for example, BioVyon.TM. (by Porvair
Filtration Group Ltd) and materials available from Porex.COPYRGT..
Further optionally, a substrate forming the fluid-transfer article
may comprise Polypropylene (PP) or Polyethylene Terephthalate
(PET).
[0527] As discussed above, the heating elements 25-4 transfer heat
to the activation surface 41-4 of the heater, thereby releasing
aerosol precursor which has reached that activation surface 41-4
through the porous polymer material of the second region 34b-4 and
the porous element 23-4 of the heater 24-4, in the form of vapor or
a mixture of vapor and aerosol. That vapor and/or mixture of vapor
and aerosol, may then pass into the air adjacent the activation
surface 41-4 and the heating elements 25-4.
[0528] FIG. 38 also illustrates an opening 38-4 in a further
housing 29-4, which opening 38-4 is in communication with the
air-intake apertures 20-4. A further opening 39-4 communicates with
a duct 40-4, which duct 40-4 communicates with the second end 18-4.
The housing 32-4 and the further housing 29-4 are separable, e.g.,
along the line B-B in FIG. 38 This allows the housing 32-4 to be
removed from the rest of the apparatus, when the aerosol precursor
in the fluid-transfer article 34-4 has been consumed. The
fluid-transfer article 34-4 can then be re-filled with aerosol
precursor, on the fluid-transfer article 34-4 replaced by one
filled with aerosol precursor. The further housing 29-4 may be
integral with the housing 26-4 containing the electrical energy
supply 28-4.
[0529] There is thus a fluid-flow path for air (hereinafter
referred to as an air-flow pathway) between openings 38-4 and 39-4,
linking the apertures 20-4 and the second end 18-4 of the aerosol
carrier. When the user sucks or inhales, air is drawn along the
air-flow pathway, along the activation surface 41-4. The housing
29-4 may include a plate 33-4 spaced from the activation surface
41-4, so that the air-flow pathway is defined between the
activation surface 41-4 and the plate 33-4.
[0530] One or more droplets of the aerosol precursor will be
released from the porous element 23-4 of the heater 24-4 and
heated, to release vapor or a mixture of aerosol and vapor into the
air flowing in the air-flow pathway between the openings 38-4,
39-4. The vapor or mixture passes, as the user sucks and inhales,
to the second end 18-4.
[0531] The porous element 33-4 of the heater 24-4 may be fibrous,
made from e.g., ceramic fiber, glass fiber or carbon fiber.
Alternatively, it may be formed from a high-temperature porous
material such as porous glass or porous ceramic.
[0532] It is thought that the flow of air between openings 38-4 and
39-4 along the activation surface 41-4 and past the heating
elements 25-4 will have the effect of creating a lower air pressure
adjacent the activation surface 41-4 which will tend to draw liquid
through the porous element 23-4 to the activation surface 41-4.
Thus, the transfer of aerosol precursor from the fluid-transfer
article 34-4 is facilitated.
[0533] As mentioned above, the heater 24-4 is separable from the
fluid-transfer article 34-4. The fluid-transfer article 34-4,
formed by the first and second regions 34a-4 and 34b-4 and any
further reservoir of aerosol precursor, may thus form a consumable
part of the apparatus, in the sense that it can readily be replaced
to enable the aerosol precursor to be replaced once it is consumed.
The heater 24-4 formed by the porous element 23-4 and the heating
elements 25-4 together with the surrounding housing 29-4 is not
part of the consumable elements.
[0534] In FIG. 38, the heating elements 25-4 may be separate or may
be interconnected to form a single heating structure. For example,
the heating elements 25-4 may be a coil, mesh or foil heater in
which the heating elements 25-4 illustrated in FIG. 38 are parts of
a common structure. Such a coil, mesh or foil heater is preferred
so that any restriction caused by the heating elements 25-4 on
release of aerosol or vapor from the activation surface is
minimized, as vapor and/or aerosol may pass through the heating
elements 25-4. However, it is also possible for the heating
elements 25-4 to be a solid unbroken strip or strips, provided that
there is then enough of the activation surface 41-4 not covered by
the heating elements 25-4 to allow sufficient release of vapor
and/or aerosol from the activation surface 41-4.
[0535] In the illustrative examples of FIG. 38, the first region
34a-4 of the fluid-transfer article 34-4 is located at an
"upstream" end of the fluid-transfer article 34-4 and the second
region 34b-4 is located at a downstream" end of the fluid-transfer
article 34-4. That is, aerosol precursor is wicked, or is drawn,
from the "upstream" end of the fluid-transfer article 34-4 to the
"downstream" end of the fluid-transfer article 34-4 (as denoted by
arrow A in FIG. 38).
[0536] In the arrangement of FIG. 38, the plate 33-4 has a planar
surface facing the activation surface 41-4. FIG. 39 illustrates an
alternative arrangement in which the plate 33-4 has projections and
recesses in its surface facing the activation surface 41-4, with
the recesses forming channels 31-4 for air to flow therethrough.
Thus, the channels 31-4 form the air-flow pathway along the
activation surface 41-4. In FIG. 39, the projections and recesses
have a square-wave or "castellated" structure. Other shapes are
possible, however, such as alternating peaks and troughs or
recesses with curved or sinusoidal walls. All such arrangements
permit channels 31-4 to be formed and allow air to flow along the
activation surface 41-4. This control of air flow improves the
mixing of the vaporized aerosol precursor into the air flow.
[0537] In the embodiment of FIG. 39, the peaks in the upper surface
of the plate 33-4 extend to the heating elements 25-4. Other
alignments are possible, and the projections need not reach all the
way to the heating elements 25-4. In general, however, the heating
elements 25-4 may restrict release of the vaporized aerosol
precursor from parts of the activation surface 41-4 on which those
heating elements 25-4 are formed, so it will normally be desirable
that the channels 31-4 are aligned with the part or parts of the
activation surface 41-4 other than the part of parts on which the
heating elements 25-4 are formed.
[0538] Note also that, in FIG. 39, the openings 38-4 and 39-4 are
not visible since they will be at the ends of the channels 31-4 to
allow air to pass from the opening 38-4 in to the channels 31-4,
and from those channels 31-4 out of the opening 39-4.
[0539] In the arrangements of FIGS. 38 and 39, the upper surface of
the porous element 23-4 of the heater 24-4 which is adjacent the
fluid-transfer article 34-4 is planar. Similarly, the lower surface
of the fluid-transfer article 34-4, which forms the transfer
surface 35-4, is also planar. Thus, the transfer surface 35-4 and
the adjacent surface of the porous element 23-4 are in intimate
contact, enabling good fluid transfer from the transfer surface to
the pores of the porous element 23-4 of the heater 24-4. Such an
arrangement is also simple to manufacture.
[0540] FIG. 40 illustrates an embodiment corresponding to that
illustrated in FIG. 38, but in which the upper surface of the
porous element 23-4 of the heater 24-4 comprises a plurality of
V-shaped or triangular projections 27-4. Then, the transfer surface
has matching V-shaped recesses in it, so that the transfer surface
35-4 follows the profiles of the projections 27-4. Thus, intimate
contact between the transfer surface 35-4 and the heater is
maintained, but the surface area of contact is increased, thereby
promoting transfer of aerosol precursor from the fluid-transfer
article 32-4 to the porous element 23-4 of the heater 24-4. Other
possible configurations for the interface between the
fluid-transfer article 32-4 and the heater 24-4 can be used, such
as "castellated" or "sinusoidal" arrangements. It is then a balance
between the increased complexity of manufacture to provide such
convoluted surfaces, and the increased fluid transfer which
results.
[0541] In the arrangements shown in FIGS. 38 to 40, the apertures
38-4, 39-4 are on opposite sides of the housing 32-4. FIGS. 41 and
42 show an alternative configuration, in which the fluid-transfer
article is annular, and both the fluid-transfer article 34-4 and
the intermediate structure 36-4 is then in the form of annulus. In
FIGS. 41 and 42, the structure of the fluid-transfer article 34-4
and the intermediate structure correspond to that shown in FIG. 38
The internal structure of fluid-transfer article 34-4 and heater
24-4 may be the same as in FIGS. 38 to 40, but is not illustrated
in detail in FIGS. 8 and 9 for simplicity. The heating elements
25-4 also cannot be seen in FIGS. 8 and 9, but may be formed as in
the arrangement of FIG. 38 or FIG. 39 However, the air flow in the
apparatus is discussed in more detail below. Thus, FIGS. 41 and 42
illustrate an aerosol carrier 14-4 according to one or more
possible arrangements in more detail. FIG. 40 is a cross-section
side view illustration of the aerosol carrier 14-4 and FIG. 41 is a
perspective cross-section side view illustration of the aerosol
carrier 14-4.
[0542] As can be seen from FIGS. 41 and 42, the aerosol carrier
14-4 is generally tubular in form. The aerosol carrier 14-4
comprises housing 32-4, which defines the external walls of the
aerosol carrier 14-4 and which defines therein a chamber in which
are disposed the fluid-transfer article 34-4 (adjacent the first
end 16-4 of the aerosol carrier 14-4) and internal walls defining
the fluid communication pathway 48-4. Fluid communication pathway
48-4 defines a fluid pathway for an outgoing air stream from the
channels 40-4 to the second end 18-4 of the aerosol carrier 14-4.
In the examples illustrated in FIGS. 41 and 42, the fluid-transfer
article 34-4 is an annular shaped element located around the fluid
communication pathway 48-4.
[0543] In walls of the housing 29-4, there are provided inlet
apertures 50-4 to provide a fluid communication pathway for an
incoming air stream to reach the activation surface 41-4 of the
heater 24-4. As is in the arrangements of FIGS. 38 to 40, the
housings 29-4 and 32-4 are separable in FIGS. 41 and 42.
[0544] In the illustrated example of FIGS. 41 and 42, the aerosol
carrier 14-4 further comprises a filter element 52-4. The filter
element 52-4 is located across the fluid communication pathway 48-4
such that an outgoing air stream passing through the fluid
communication pathway 48-4 passes through the filter element
52-4.
[0545] With reference to FIG. 41, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18-4 of the aerosol carrier
14-4, if configured as a mouthpiece), air is drawn into the carrier
through inlet apertures 50-4 extending through walls in the housing
29-4 of the aerosol carrier 14-4.
[0546] An incoming airstream 42a-4 from a first side of the aerosol
carrier 14-4 is directed to a first side of the heater 24-4 (e.g.,
via a gas communication pathway within the housing of the carrier).
An incoming air stream 42b-4 from a second side of the aerosol
carrier 14-4 is directed to a second side of the heater 24-4 (e.g.,
via a gas communication pathway within the housing of the carrier).
When the incoming air stream 42a-4 from the first side of the
aerosol carrier 14-4 reaches the first side of the heater 24-4, the
incoming air stream 42a-4 from the first side of the aerosol
carrier 14-4 flows along the activation surface of the heater 24-4.
Likewise, when the incoming air stream 42b-4 from the second side
of the aerosol carrier 14-4 reaches the second side of the heater
24-4, the incoming air stream 42b-4 from the second side of the
aerosol carrier 14-4 flows along the activation surface of the
heater 24-4. The air streams from each side are denoted by dashed
lines 44a-4 and 44b-4 in FIG. 41 As these air streams 44a-4 and
44b-4 flow, aerosol precursor on the activation surface 41-4 of the
heater 24-4 is entrained in air streams 44a-4 and 44b-4.
[0547] In use, the heating elements 25-4 of the apparatus 12-4
raise the temperature of the porous element 23-4 of the heater 24-4
to a sufficient temperature to release, or liberate, captive
substances (i.e., the aerosol precursor) to form a vapor and/or
aerosol, which is drawn downstream. As the air streams 44a-4 and
44b-4 continue their passages, more released aerosol precursor is
entrained within the air streams 44a-4 and 44b-4. When the air
streams 44a-4 and 44b-4 entrained with aerosol precursor meet at a
mouth of the outlet fluid communication pathway 48-4, they enter
the outlet fluid communication pathway 48-4 and continue until they
pass through filter element 52-4 and exit outlet fluid
communication pathway 48-4, either as a single outgoing air stream,
or as separate outgoing air streams 46-4 (as shown). The outgoing
air streams 46-4 are directed to an outlet, from where it can be
inhaled by the user directly (if the second end 18-4 of the aerosol
capsule 14-4 is configured as a mouthpiece), or via a mouthpiece.
The outgoing air streams 46-4 entrained with aerosol precursor are
directed to the outlet (e.g., via a gas communication pathway
within the housing of the carrier).
[0548] FIG. 33 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10-4.
[0549] As will be appreciated, in the arrangements described above,
the fluid-transfer article 34-4 is provided within a housing 32-4
of the aerosol carrier 14-4. In such arrangements, the housing of
the carrier 14-4 serves to protect the aerosol precursor-containing
fluid-transfer article 34-4, whilst also allowing the carrier 14-4
to be handled by a user without his/her fingers coming into contact
with the aerosol precursor liquid retained therein.
[0550] In any of the embodiments described above the second region
34b-4 may have a thickness of less than 5 mm. In other embodiments
it may have a thickness of: less than 3.5 mm, less than 3 mm, less
than 2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8 mm,
less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4
mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than
1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less
than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm,
less than 0.2 mm, or less than 0.1 mm.
[0551] Fifth Mode: A Fluid Transfer Article Comprising a First
Region Having an Aerosol Precursor and for Transferring Said
Aerosol Precursor to an Activation Surface of a Second Region of
Said Article
[0552] Aspects and embodiments of the fifth mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the fifth mode will be
apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0553] In general outline, one or more embodiments of the fifth
mode in accordance with the present disclosure may provide a system
for aerosol delivery in which an aerosol carrier may be inserted
into a receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier. Another end, or another end portion, of the aerosol
carrier may protrude from the apparatus and can be inserted into
the mouth of a user for the inhalation of aerosol released from the
aerosol carrier cartridge during operation of the apparatus.
[0554] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
[0555] Referring now to FIG. 44, there is illustrated a perspective
view of an aerosol delivery system 10-5 comprising an aerosol
generation apparatus 12-5 operative to initiate and maintain
release of aerosol from a fluid-transfer article in an aerosol
carrier 14-5. In the arrangement of FIG. 44, the aerosol carrier
14-5 is shown with a first end 16-5 thereof and a portion of the
length of the aerosol carrier 14-5 located within a receptacle of
the apparatus 12-5. A remaining portion of the aerosol carrier 14-5
extends out of the receptacle. This remaining portion of the
aerosol carrier 14-5, terminating at a second end 18-5 of the
aerosol carrier, is configured for insertion into a user's mouth. A
vapor and/or aerosol is produced when a heater (not shown in FIG.
44) of the apparatus 12-5 heats a fluid-transfer article in the
aerosol carrier 14-5 to release a vapor and/or an aerosol, and this
can be delivered to the user, when the user sucks or inhales, via a
fluid passage in communication with an outlet of the aerosol
carrier 14-5 from the fluid-transfer article to the second end
18-5.
[0556] The device 12-5 also comprises air-intake apertures 20-5 in
the housing of the apparatus 12-5 to provide a passage for air to
be drawn into the interior of the apparatus 12-5 (when the user
sucks or inhales) for delivery to the first end 16-5 of the aerosol
carrier 14-5, so that the air can be drawn across an activation
surface of a fluid-transfer article located within a housing of the
aerosol carrier cartridge 14-5 during use. Optionally, these
apertures may be perforations in the housing of the apparatus
12-5.
[0557] A fluid-transfer article 34-5 (not shown in FIG. 44, but
described hereinafter with reference to FIGS. 48 to 51 is located
within a housing of the aerosol carrier 14-5. The fluid-transfer
article 34-5 contains an aerosol precursor material, which may
include at least one of: nicotine; a nicotine precursor material; a
nicotine compound; and one or more flavorings. The aerosol
precursor of the fluid-transfer article 34-5 is in the unheated
state where the heater (not shown in FIG. 44) is not active and the
aerosol near the activation surface is at ambient temperature and
pressure. The aerosol precursor near the activation surface has a
dynamic viscosity such that the aerosol precursor is substantially
retained in the fluid-transfer article and does not leave the
activation surface. On application of a pressure below atmospheric
pressure the aerosol precursor in the unheated state is also
substantially retained in the fluid-transfer article and is not
drawn from the activation surface. The fluid-transfer article 34-5
is located within the housing of the aerosol carrier 14-5 to allow
air drawn into the aerosol carrier 14-5 at, or proximal, the first
end 16-5, and has first and second regions, as will be
described.
[0558] The first region of the fluid-transfer article 34-5 may
comprise a substrate of porous material where pores of the porous
material hold, contain, carry, or bear the aerosol precursor
material. In particular, the porous material of the fluid-transfer
article may be a porous polymer material such as, for example, a
sintered material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET). All such
materials may be described as heat resistant polymeric wicking
material in the context of the present disclosure.
[0559] Alternatively, in some embodiments it is envisaged that the
first region of the fluid-transfer article 34-5 may take the form
of a simple tank having a cavity defining a hollow reservoir to
hold the aerosol precursor.
[0560] The aerosol carrier 14-5 is removable from the apparatus
12-5 so that it may be disposed of when expired. After removal of a
used aerosol carrier 14-5, a replacement aerosol carrier 14-5 can
be inserted into the apparatus 12-5 to replace the used aerosol
carrier 14-5.
[0561] FIG. 45 is a cross-sectional side view illustration of a
part of apparatus 12-5 of the aerosol delivery system 10-5. The
apparatus 12-5 comprises a receptacle 22-5 in which is located a
portion of the aerosol carrier 14-5. In one or more optional
arrangements, the receptacle 22-5 may enclose the aerosol carrier
14-5. The apparatus 12-5 also comprises a heater 24-5, which is in
contact with an activation surface of the fluid-transfer article
34-5 when an aerosol carrier 14-5 is located within the receptacle
22-5. Optional configurations of the heater 24-5 will be discussed
later.
[0562] Air flows into the apparatus 12-5 (in particular, into a
closed end of the receptacle 22-5) via air-intake apertures 20-5.
From the closed end of the receptacle 22-5, the air is drawn into
the aerosol carrier 14-5 (under the action of the user inhaling or
sucking on the second end 18-5) and expelled at the second end
18-5. As the airflows into the aerosol carrier 14-5, it passes
across the activation surface. Heat from the heater 24-5, which is
in contact with the activation surface of the fluid-transfer
article 34-5, causes vaporization of aerosol precursor material at
the activation surface of the fluid-transfer article 34-5 and an
aerosol is created in the air flowing over the activation surface.
Thus, through the application of heat to the activation surface, an
aerosol is released, or liberated, from the fluid-transfer article,
and is drawn from the material of the aerosol carrier unit by the
air flowing across the activation surface and is transported in the
air flow to via outlet conduits (not shown in FIG. 45) in the
housing of the aerosol carrier 14-5 to the second end 18-5. The
direction of airflow is illustrated by arrows in FIG. 45.
[0563] To achieve release of the captive aerosol from the
fluid-transfer article, the activation surface of the
fluid-transfer article 34-5 is heated by the heater 24-5. As a user
sucks or inhales on second end 18-5 of the aerosol carrier 14-5,
the aerosol released from the fluid-transfer article and entrained
in the air flowing across the activation surface is drawn through
the outlet conduits (not shown) in the housing of the aerosol
carrier 14-5 towards the second end 18-5 and onwards into the
user's mouth.
[0564] Turning now to FIG. 46, a cross-sectional side view of the
aerosol delivery system 10-5 is schematically illustrated showing
the features described above in relation to FIGS. 44 and 45 in more
detail. As can be seen, apparatus 12-5 comprises a housing 26-5, in
which is located the receptacle 22-5. The housing 26-5 also
contains control circuitry (not shown) operative by a user, or upon
detection of air and/or vapor being drawn into the device 12-5
through air-intake apertures 20-5, i.e., when the user sucks or
inhales. Additionally, the housing 26-5 comprises an electrical
energy supply 28-5, for example a battery. Optionally, the battery
comprises a rechargeable lithium-ion battery. The housing 26-5 also
comprises a coupling 30-5 for electrically (and optionally
mechanically) coupling the electrical energy supply 28-5 to control
circuitry (not shown) for powering and controlling operation of the
heater 24-5.
[0565] Responsive to activation of the control circuitry of
apparatus 12-5, the heater 24-5 heats the activation surface of the
fluid-transfer article 34-5 (not shown in FIG. 46). This heating
process initiates (and, through continued operation, maintains)
release of vapor and/or an aerosol from the activation surface of
the fluid-transfer article 34-5. The vapor and/or aerosol formed as
a result of the heating process is entrained into a stream of air
being drawn across the activation surface of the fluid-transfer
article 34-5 (as the user sucks or inhales). The stream of air with
the entrained vapor and/or aerosol passes through the aerosol
carrier 14-5 via outlet conduits (not shown) and exits the aerosol
carrier 14-5 at second end 18-5 for delivery to the user. This
process is briefly described above in relation to FIG. 45, where
arrows schematically denote the flow of the air stream into the
device 12-5 and through the aerosol carrier 14-5, and the flow of
the air stream with the entrained vapor and/or aerosol through the
aerosol carrier cartridge 14-5.
[0566] FIGS. 47 to 49 schematically illustrate the aerosol carrier
14-5 in more detail (and, in FIGS. 48 and 49, features within the
receptacle in more detail). FIG. 47 illustrates an exterior of the
aerosol carrier 14-5, FIG. 48 illustrates internal components of
the aerosol carrier 14-5 in one optional configuration, and FIG. 49
illustrates internal components of the aerosol carrier 14-5 in
another optional configuration.
[0567] FIG. 47 illustrates the exterior of the aerosol carrier
14-5, which comprises housing 32-5 for housing said fluid-transfer
article (not shown). The particular housing 32-5 illustrated in
FIG. 47 comprises a tubular member, which may be generally
cylindrical in form, and which is configured to be received within
the receptacle of the apparatus. First end 16-5 of the aerosol
carrier 14-5 is for location to oppose the heater of the apparatus,
and second end 18-5 (and the region adjacent the second end 18-5)
is configured for insertion into a user's mouth.
[0568] FIG. 48 illustrates some internal components of the aerosol
carrier 14-5 and of the heater 24-5 of apparatus 12-5, in one
embodiment of the disclosure.
[0569] As described above, the aerosol carrier 14-5 comprises a
fluid-transfer element 34-5. At least part of the fluid-transfer
article 34-5 may be removable from the housing 32-5, to enable it
to be replaced. The fluid-transfer article 34-5 acts as a reservoir
for aerosol precursor and that aerosol precursor will be consumed
as the apparatus is used. Once sufficient aerosol precursor has
been consumed, the aerosol precursor will need to be replaced. It
may then be easiest to replace it by replacing the fluid-transfer
article 34-5, rather than trying to re-fill the fluid-transfer
article 34-5 with aerosol precursor while it is in the housing
32-5.
[0570] In the illustrated embodiments, the fluid-transfer article
34-5 has a first region 35-5 formed by layers 35a-5 and 35b-5, and
a second region 36-5. That second region 36-5 has a first part
being an upper layer 36a-5 which is formed by a plate with a
plurality of holes 37-5 therein, and a second part being a lower
layer formed by a second plate 36b-5 made of a porous material
which allows aerosol precursor to pass therethrough. In the
arrangement of FIG. 48, the plate 36a-5 with holes 37-5 therein is
in contact with the first region 35-5 of the fluid-transfer article
34-5, so that aerosol precursor may pass from that first region
35-5 directly into the holes 37-5, and through those holes to the
second plate 36b-5.
[0571] Since the second plate 36b-5 is porous, the aerosol
precursor will pass to the surface of the plate 36b-5 remote from
the first region 35-5 of the fluid-transfer article 34-5, which
surface acts as an activation surface 41-5 of the fluid-transfer
article 34-5. One or more heaters 24-5 are mounted on the
activation surface 41-5. When the heater or heaters 24-5 are
activated, the heat which they generate will be transferred to the
activation surface 41-5.
[0572] Further components not shown in FIG. 48 comprise: an inlet
conduit, via which air can be drawn into the aerosol carrier 14-5;
an outlet conduit, via which an air stream entrained with aerosol
can be drawn from the aerosol carrier 14-5; a filter element; and a
reservoir for storing aerosol precursor material and for providing
the aerosol precursor material to the fluid-transfer article
34-5.
[0573] In FIG. 48, the aerosol carrier is shown as comprising the
fluid-transfer article 34-5 located within housing 32. The fluid
transfer article 34-5 comprises a first region 35-5 holding an
aerosol precursor. In one or more arrangements, the first region of
35 of the fluid transfer article 34-5 comprises a reservoir holding
the aerosol precursor. The first region 35-5 can be the sole
reservoir of the aerosol carrier 14-5, or it can be arranged in
fluid communication with a separate reservoir, where aerosol
precursor is stored for supply to the first region 35-5. As shown
in FIG. 48, the first region 35-5 has a first layer 35a-5 and a
second layer 35b-5. The material forming the first layer 35a-5 of
the first region 35-5 comprises a porous structure, whose pore
diameter size varies between one end of the first layer 35a-5 and
another end of the first layer 35a-5. The pore diameter size may
increase from a first end remote from heater or heaters 24-5 (the
upper end is as shown in the figure) to a second end. The pore
diameter size may change in a step-wise manner (i.e., a first part
with pores having a diameter of first size, and a second part with
pores having a diameter of second, smaller size), or the change in
pore size in the first layer 35a-5 may be gradual rather than
step-wise. This configuration of pores having a decreasing diameter
size can provide a wicking effect, which can serve to draw fluid
through the first layer 35a-5, towards heater or heaters 24-5.
[0574] The first region 35-5 of the fluid transfer article 34-5 may
also comprise a second layer 35b-5. Aerosol precursor is drawn from
the first layer 35a-5 to the second layer 35b-5 by the wicking
effect of the material forming the first layer 35a-5. Thus, the
first layer 35a-5 is configured to transfer the aerosol precursor
to the second layer 35b-5 of the first region 35-5 of the
fluid-transfer article 34-5.
[0575] The second layer 35b-5 itself may comprise a porous
structure formed by a porous polymer material. It is then
preferable that the pore diameter size of the porous structure of
the second layer 35b-5 is smaller than the pore diameter size of
the immediately adjacent part of the first layer 35a-5. As
mentioned above, the porous polymer material may be a sintered
material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET).
[0576] However, as mentioned previously, in some embodiments it is
envisaged that the first region 35-5 of the fluid-transfer article
need not be of porous polymer material as described above. Instead,
the first region 35-5 of the fluid-transfer article 34-5 may take
the form of a simple tank having a cavity defining a hollow
reservoir to hold the aerosol precursor. In such embodiments it is
proposed that the plate 36a-5 with holes 37-5 therein will extend
across the bottom of the tank so that aerosol precursor held in the
tank will impinge directly on the plate 36a-5 and pass directly
from the tank defining the first region 35-5 of the fluid-transfer
article 34-5 into the holes 37-5 of the second region 36-5 of the
fluid-transfer article.
[0577] As discussed above, the heater or heaters 24-5 transfer heat
to the activation surface 41-5, thereby releasing aerosol precursor
which has reached that activation surface 41-5 from the porous
polymer material (or hollow reservoir) of the first region 35-5,
through the second region 36-5. That vapor and/or a mixture of
vapor and aerosol, may then pass into the air adjacent the
activation surface 41-5 and the heater or heaters 24-5.
[0578] FIG. 48 also illustrates an opening 38-5, which opening 38-5
is in communication with the air-intake apertures 20-5. A further
opening 39-5 communicates with a duct 40-5 within the housing 32-5,
which duct 40-5 communicates with the second end 18-5.
[0579] There is thus a fluid-flow path for air (referred to as an
air-flow pathway) between openings 38-5 and 39-5, linking the
apertures 20-5 and the second end 18-5 of the aerosol carrier. When
the user sucks or inhales, air is drawn along the air-flow pathway,
along the activation surface 41-5. A plate 33-5 forms a lower
surface of the air-flow pathway, the plate 33-5 being spaced from
the activation surface 41-5. It can be seen that the air-flow
pathway is in direct contact with parts of the activation surface
41-5, as the heater or heaters 24-5 may partially block that path
from the activation surface to the fluid flow pathway. The fluid
flow pathway is on the opposite side of the heater or heaters 24-5
from the activation surface 41-5, so vapor must pass around the
heater or heaters 24-5 if it cannot pass therethrough.
[0580] One or more droplets of the aerosol precursor will be
released from the second plate 36b-5 and heated, to release vapor
or a mixture of aerosol and vapor into the air flowing in the
air-flow pathway between the openings 38-5, 39-5. The vapor or
mixture passes, as the user sucks and inhales, to the second end
18-5.
[0581] As mentioned above, the second region 36-5 of the
fluid-transfer article 34-5 comprises a first plate 36a-5 and a
second plate 36b-5. The first plate 36a-5 may be a molded polymer
disc so that is then easy to form the holes 37-5 therein by molding
the holes 37-5 when the plate 36a-5 is itself molded. The holes
37-5 are sufficiently large that they do not act as a capillary,
but instead define non-capillary spaces in the second region 36-5.
Hence, aerosol precursor is able to pass from the first region 35-5
of the fluid-transfer article to the second region 36-5 in a
non-capillary manner, into the holes 37-5, and then pass through
the second plate 36b-5 to the heater or heaters 24-5. The holes
37-5 may be relatively large, so that they fill with aerosol
precursor when the apparatus is in use.
[0582] The second plate 36b-5 is made of a porous material which is
more heat-resistant than the material of the plate 36a-5, as it is
acted on directly by the heater or heaters 24-5. It may be fibrous,
made from e.g., ceramic fiber, glass fiber or carbon fiber.
Alternatively, it may be formed from a high-temperature porous
material such as porous glass or porous ceramic. Another
possibility is that the second plate 36b-5 may be of a porous
polymer material, such as the materials described previously with
reference to the layers 35a-5 and 35b-5 of the first region 35-5,
provided that the polymer material is sufficiently resistant to the
high temperatures to which it will be subject due to the heater or
heaters 24-5.
[0583] It is thought that the flow of air between openings 38-5 and
39-5 along the activation surface 41-5 and past the heater or
heaters 24-5 will have the effect of creating the lower air
pressure adjacent the activation surface 41-5 which will tend to
draw liquid through the porous second plate 36b-5 to the activation
surface 41-5. Thus, the transfer of aerosol precursor from the
fluid-transfer article 34-5 is facilitated.
[0584] As mentioned above, the fluid-transfer article 34-5, formed
by the first and second regions 35-5 and 36-5 and any further
reservoir of aerosol precursor, forms the consumable part of the
apparatus, in the sense that it can readily be replaced to enable
the aerosol precursor to be replaced once it is consumed. The
heater or heaters 24-5 are not part of the consumable elements.
Thus, the housing 32-5 containing the fluid-transfer article 34-5
may be separable from a housing 43-5 supporting the heater or
heaters 24-5 along the line B-B in FIG. 48 The plate 33-5 may be
integral with the further housing 43-5, and the openings 38-5 and
39-5 are formed in the further housing 43-5. The further housing
43-5 may be integral with the housing 26-5 containing the
electrical energy supply 28-5. It is for this reason that the
heater or heaters 24-5 make contact with, but are not bonded to,
the activation surface 41-5. The contact ensures the most efficient
heat transfer from the heater or heaters 24-5 to the second plate
36b-5 to heat the activation surface 41-5 but the heater or heaters
24-5 must be separable from that activation surface 41-5 to allow
removal of the housing 32-5 from the further housing 43-5 when the
fluid-transfer article 34-5 has become depleted. The line B to B
may therefore correspond to the plane of the activation surface
41-5.
[0585] In FIG. 48, the heater or heaters 24-5 may be separate or be
interconnected to form a single heater. For example, the heater may
be a coil, mesh or foil heater in which the parts of the heater
24-5 illustrated in FIG. 48 may be parts of a common structure.
Such a coil, mesh or foil heater is preferred so that any
restriction caused by the heater or heaters 24-5 on release of
aerosol or vapor from the activation surface is minimized, as vapor
and/or aerosol may pass through the heater or heaters 24-5.
However, it is also possible for the heater or heaters 24-5 to be a
solid unbroken strip or strips, provided that there is then enough
of the activation surface 41-5 not covered by the heater or heaters
24-5 to allow sufficient release of vapor and/or aerosol from the
activation surface 41-5.
[0586] In the illustrative examples of FIG. 48, the first layer
35a-5 of the first region 35-5 of the fluid-transfer article 34-5
is located at an "upstream" end of the fluid-transfer article 34-5
and the second plate 35b-5 of the second region 35b-5 is located at
a downstream" end of the fluid-transfer article 34-5. That is,
aerosol precursor is wicked, or is drawn, from the "upstream" end
of the fluid-transfer article 34-5 to the "downstream" end of the
fluid-transfer article 34-5 (as denoted by arrow A in FIG. 48).
[0587] In the arrangement of FIG. 48, the plate 33-5 has a planar
surface facing the activation surface 41-5. FIG. 49 illustrates an
arrangement in which the plate 33-5 has projections and recesses in
its upper surface, so that the recesses can form channels 31-5 for
air to flow therethrough. Other features which are the same as
those of FIG. 48 are indicated by the same reference numerals.
Thus, the channels 31-5 form the air-flow pathway along the
activation surface 41-5. In FIG. 49, the projections and recesses
form a square-wave or "castellated" structure. Further shapes are
possible, however, such as alternating peaks and troughs or
recesses with curved walls. All such arrangements permit channels
31-5 to be formed and allow air to flow along the activation
surface 41-5. This control of air flow improves the mixing of the
vaporized aerosol precursor into the air flow.
[0588] In the embodiment of FIG. 49, the peaks in the upper surface
of the plate 33-5 extend to the heater or heaters 24-5, with the
recesses between those peaks which form the channels 31-5 then
being aligned with the holes 37-5 formed in the second plate 35b-5
of the fluid-transfer article 34-5. Other alignments are possible,
and the projections need not reach all the way to the heater or
heaters 24-5. In general, however, the heater or heaters 24-5 may
restrict release of the vaporized aerosol precursor from parts of
the activation surface 41-5 on which those heater or heaters 24-5
are formed, so it will normally be desirable that the channels 31-5
are aligned with the part or parts of the activation surface 41-5
other than the part or parts on which the heater or heaters 24-5
are formed.
[0589] Note also that, in FIG. 49, the openings 38-5 and 39-5 are
not visible since they will be at the ends of the channels 31-5 to
allow air to pass from the opening 38-5 in to the channels 31-5,
and from those channels 31-5 out of the opening 39-5. Also, as in
FIG. 48, the housing 32-5 containing the fluid-transfer article
34-5 may be separable from the housing 43-5 containing the
intermediate structure 36-5 and the heater or heaters 24-5 along
the line B-B in FIG. 49.
[0590] In the arrangements shown in FIGS. 48 and 49, the apertures
38-5, 39-5 are on opposite sides of the housing 32-5. FIGS. 50 and
51 shows an alternative configuration, in which the fluid-transfer
article is annular, and both the first region 35-5 and the second
region 36-5 are then in the form of annuli. In FIGS. 51 and 52, the
structure of the fluid-transfer article 34-5, including the first
region 35-5 and the second region 36-5 may correspond generally to
that shown in FIG. 48 The internal structure of the first and
second regions 35-5 and 36-5 may be the same as in FIG. 48, but are
not illustrated in detail in FIGS. 50 and 51 for simplicity. The
heater or heaters 24-5 also cannot be seen in FIGS. 50 and 51, but
may be formed as in the arrangement of FIG. 48 or FIG. 49 However,
the air flow in the apparatus is discussed in more detail below.
Thus, FIGS. 50 and 51 illustrate an aerosol carrier 14-5 according
to one or more possible arrangements in more detail. FIG. 50 is a
cross-section side view illustration of the aerosol carrier 14-5
and FIG. 51 is a perspective cross-section side view illustration
of the aerosol carrier 14-5.
[0591] As can be seen from FIGS. 50 and 51, the aerosol carrier
14-5 is generally tubular in form. The aerosol carrier 14-5
comprises housing 32-5, which defines the external walls of the
aerosol carrier 14-5 and which defines therein a chamber in which
are disposed the fluid-transfer article 34-5 (adjacent the first
end 16-5 of the aerosol carrier 14-5) and internal walls defining
the fluid communication pathway 48-5. Fluid communication pathway
48-5 defines a fluid pathway for an outgoing air stream from the
channels 40-5 to the second end 18-5 of the aerosol carrier 14-5.
In the examples illustrated in FIGS. 50 and 51, the fluid-transfer
article 34-5 is an annular shaped element located around the fluid
communication pathway 48-5. The housing 32-5 containing the
fluid-transfer article 34-5 is separable from the housing 43-5
supporting heater or heaters 24-5.
[0592] In walls of the housing 43-5, there are provided inlet
apertures 50-5 to provide a fluid communication pathway for an
incoming air stream to reach the activation surface 41-5 of the
second region 36-5 of the fluid-transfer article 34-5.
[0593] In the illustrated example of FIGS. 50 and 51, the aerosol
carrier 14-5 further comprises a filter element 52-5. The filter
element 52-5 is located across the fluid communication pathway 48-5
such that an outgoing air stream passing through the fluid
communication pathway 48-5 passes through the filter element
52-5.
[0594] With reference to FIG. 51, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18-5 of the aerosol carrier
14-5, if configured as a mouthpiece), air is drawn into the carrier
through inlet apertures 50-5 extending through walls in the housing
32-5 of the aerosol carrier 14-5.
[0595] An incoming airstream 42a-5 from a first side of the aerosol
carrier 14-5 is directed to a first side of the second region 36-5
(e.g., via a gas communication pathway within the housing of the
carrier). An incoming air stream 42b-5 from a second side of the
aerosol carrier 14-5 is directed to a second side of the second
region 36-5 (e.g., via a gas communication pathway within the
housing of the carrier). When the incoming air stream 42a-5 from
the first side of the aerosol carrier 14-5 reaches the first side
of the second region 36-5, the incoming air stream 42a-5 from the
first side of the aerosol carrier 14-5 flows along the activation
surface 41-5 of the second region 36-5. Likewise, when the incoming
air stream 42b-5 from the second side of the aerosol carrier 14-5
reaches the second side of the second region 36-5, the incoming air
stream 42b-5 from the second side of the aerosol carrier 14-5 flows
along the activation surface 41-5 of the second region 36-5. The
air streams from each side are denoted by dashed lines 44a-5 and
44b-5 in FIG. 51 As these air streams 44a-5 and 44b-5 flow, aerosol
precursor on the activation surface 41-5 of the second region 36-5
is entrained in air streams 44a-5 and 44b-5.
[0596] In use, the heater or heaters 24-5 of the apparatus 12-5
raise a temperature of the second plate 36b-5 of the second region
36-5 to a sufficient temperature to release, or liberate, captive
substances (i.e., the aerosol precursor) to form a vapor and/or
aerosol, which is drawn downstream. The heater or heaters 24-5
modify the captive substances (i.e., the aerosol precursor) from an
unheated state to a heated state. As the air streams 44a-5 and
44b-5 continue their passages, more released aerosol precursor is
entrained within the air streams 44a-5 and 44b-5. When the air
streams 44a-5 and 44b-5 entrained with aerosol precursor meet at a
mouth of the outlet fluid communication pathway 48-5, they enter
the outlet fluid communication pathway 48-5 and continue until they
pass through filter element 52-5 and exit outlet fluid
communication pathway 48-5, either as a single outgoing air stream,
or as separate outgoing air streams 46-5 (as shown). The outgoing
air streams 46-5 are directed to an outlet, from where it can be
inhaled by the user directly (if the second end 18-5 of the aerosol
capsule 14-5 is configured as a mouthpiece), or via a mouthpiece.
The outgoing air streams 46-5 entrained with aerosol precursor are
directed to the outlet (e.g., via a gas communication pathway
within the housing of the carrier).
[0597] FIG. 52 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10-5.
[0598] As will be appreciated, in the arrangements described above,
the fluid-transfer article 34-5 is provided within a housing 32-5
of the aerosol carrier 14-5. In such arrangements, the housing of
the carrier 14-5 serves to protect the aerosol precursor-containing
fluid-transfer article 34-5, whilst also allowing the carrier 14-5
to be handled by a user without his/her fingers coming into contact
with the aerosol precursor liquid retained therein.
[0599] In any of the embodiments described above the second plate
36b-5 of the second region 36-5 may have a thickness of less than 5
mm. In other embodiments it may have a thickness of: less than 3.5
mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9
mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than
1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less
than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm,
less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4
mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.
[0600] Sixth Mode: An Aerosol Generation Apparatus has a
Fluid-Transfer Article with a First Region which Holds an Aerosol
Precursor
[0601] Aspects and embodiments of the sixth mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the sixth mode will be
apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0602] In general outline, one or more embodiments in accordance
with the present disclosure may provide a system for aerosol
delivery in which an aerosol carrier may be inserted into a
receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier. Another end, or another end portion, of the aerosol
carrier may protrude from the apparatus and can be inserted into
the mouth of a user for the inhalation of aerosol released from the
aerosol carrier cartridge during operation of the apparatus.
[0603] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
[0604] Referring now to FIG. 53, there is illustrated a perspective
view of an aerosol delivery system 10-6 comprising an aerosol
generation apparatus 12-6 operative to initiate and maintain
release of aerosol from a fluid-transfer article in an aerosol
carrier 14-6. In the arrangement of FIG. 53, the aerosol carrier
14-6 is shown with a first end 16-6 thereof and a portion of the
length of the aerosol carrier 14-6 located within a receptacle of
the apparatus 12-6. A remaining portion of the aerosol carrier 14-6
extends out of the receptacle. This remaining portion of the
aerosol carrier 14-6, terminating at a second end 18-6 of the
aerosol carrier, is configured for insertion into a user's mouth. A
vapor and/or aerosol is produced when a heater (not shown in FIG.
53) of the apparatus 12-6 heats a fluid-transfer article in the
aerosol carrier 14-6 to release a vapor and/or an aerosol, and this
can be delivered to the user, when the user sucks or inhales, via a
fluid passage in communication with an outlet of the aerosol
carrier 14-6 from the fluid-transfer article to the second end
18-6.
[0605] The device 12-6 also comprises air-intake apertures 20-6 in
the housing of the apparatus 12-6 to provide a passage for air to
be drawn into the interior of the apparatus 12-6 (when the user
sucks or inhales) for delivery to the first end 16-6 of the aerosol
carrier 14-6, so that the air can be drawn across an activation
surface of a fluid-transfer article located within a housing of the
aerosol carrier cartridge 14-6 during use. Optionally, these
apertures may be perforations in the housing of the apparatus
12-6.
[0606] A fluid-transfer article 34-6 (not shown in FIG. 53, but
described hereinafter with reference to FIGS. 57 to 59 is located
within a housing of the aerosol carrier 14-6. The fluid-transfer
article 34-6 contains an aerosol precursor material, which may
include at least one of: nicotine; a nicotine precursor material; a
nicotine compound; and one or more flavorings. The fluid-transfer
article 34-6 is located within the housing of the aerosol carrier
14-6 to allow air drawn into the aerosol carrier 14-6 at, or
proximal, the first end 16-6, and has first and second regions, as
will be described.
[0607] The first region of the fluid-transfer article 34-6 may
comprise a substrate of porous material where pores of the porous
material hold, contain, carry, or bear the aerosol precursor
material. In particular, the porous material of the fluid-transfer
article may be a porous polymer material such as, for example, a
sintered material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET). All such
materials may be described as heat resistant polymeric wicking
material in the context of the present disclosure.
[0608] Alternatively, in some embodiments it is envisaged that the
first region of the fluid-transfer article 34-6 may take the form
of a simple tank having a cavity defining a hollow reservoir to
hold the aerosol precursor.
[0609] The aerosol carrier 14-6 is removable from the apparatus
12-6 so that it may be disposed of when expired. After removal of a
used aerosol carrier 14-6, a replacement aerosol carrier 14-6 can
be inserted into the apparatus 12-6 to replace the used aerosol
carrier 14-6.
[0610] FIG. 54 is a cross-sectional side view illustration of a
part of apparatus 12-6 of the aerosol delivery system 10-6. The
apparatus 12-6 comprises a receptacle 22-6 in which is located a
portion of the aerosol carrier 14-6. In one or more optional
arrangements, the receptacle 22-6 may enclose the aerosol carrier
14-6. The apparatus 12-6 also comprises a heater 24-6, which
interacts thermally with an activation surface of the
fluid-transfer article 34-6 when an aerosol carrier 14-6 is located
within the receptacle 22-6.
[0611] Air flows into the apparatus 12-6 (in particular, into a
closed end of the receptacle 22-6) via air-intake apertures 20-6.
From the closed end of the receptacle 22-6, the air is drawn into
the aerosol carrier 14-6 (under the action of the user inhaling or
sucking on the second end 18-6) and expelled at the second end
18-6. As the air flows into the aerosol carrier 14-6, it passes
across the activation surface. Heat from the heater 24-6 heats the
activation surface of the fluid-transfer article 34-6, which causes
vaporization of aerosol precursor material at the activation
surface of the fluid-transfer article 34-6 and an aerosol is
created in the air flowing over the activation surface. Thus,
through the application of heat to the activation surface, an
aerosol is released, or liberated, from the fluid-transfer article,
and is drawn from the material of the aerosol carrier unit by the
air flowing across the activation surface and is transported in the
air flow to via outlet conduits (not shown in FIG. 54) in the
housing of the aerosol carrier 14-6 to the second end 18-6. The
direction of air flow is illustrated by arrows in FIG. 54.
[0612] To achieve release of the captive aerosol from the
fluid-transfer article, the activation surface of the
fluid-transfer article 34-6 is heated by the heater 24-6. As a user
sucks or inhales on second end 18-6 of the aerosol carrier 14-6,
the aerosol released from the fluid-transfer article and entrained
in the air flowing across the activation surface is drawn through
the outlet conduits (not shown) in the housing of the aerosol
carrier 14-6 towards the second end 18-6 and onwards into the
user's mouth.
[0613] Turning now to FIG. 55, a cross-sectional side view of the
aerosol delivery system 10-6 is schematically illustrated showing
the features described above in relation to FIGS. 53 and 54 in more
detail. As can be seen, apparatus 12-6 comprises a housing 26-6, in
which is located the receptacle 22-6. The housing 26-6 also
contains control circuitry (not shown) operative by a user, or upon
detection of air and/or vapor being drawn into the device 12-6
through air-intake apertures 20-6, i.e., when the user sucks or
inhales. Additionally, the housing 26-6 comprises an electrical
energy supply 28-6, for example a battery. Optionally, the battery
comprises a rechargeable lithium-ion battery. The housing 26-6 also
comprises a coupling 30-6 for electrically (and optionally
mechanically) coupling the electrical energy supply 28-6 to control
circuitry (not shown) for powering and controlling operation of the
heater 24-6.
[0614] Responsive to activation of the control circuitry of
apparatus 12-6, the heater 24-6 heats the activation surface of the
fluid-transfer article 34-6 (not shown in FIG. 55). This heating
process initiates (and, through continued operation, maintains)
release of vapor and/or an aerosol from the activation surface of
the fluid-transfer article 34-6. The vapor and/or aerosol formed as
a result of the heating process is entrained into a stream of air
being drawn across the activation surface of the fluid-transfer
article 34-6 (as the user sucks or inhales). The stream of air with
the entrained vapor and/or aerosol passes through the aerosol
carrier 14-6 via outlet conduits (not shown) and exits the aerosol
carrier 14-6 at second end 18-6 for delivery to the user. This
process is briefly described above in relation to FIG. 54, where
arrows schematically denote the flow of the air stream into the
device 12-6 and through the aerosol carrier 14-6, and the flow of
the air stream with the entrained vapor and/or aerosol through the
aerosol carrier cartridge 14-6.
[0615] FIGS. 56 and 57 schematically illustrate the aerosol carrier
14-6 in more detail (and, in FIG. 57, features within the
receptacle in more detail). FIG. 56 illustrates an exterior of the
aerosol carrier 14-6, and FIG. 57 illustrates internal components
of the aerosol carrier 14-6 in one optional configuration.
[0616] FIG. 56 illustrates the exterior of the aerosol carrier
14-6, which comprises housing 32-6 for housing said fluid-transfer
article (not shown). The particular housing 32-6 illustrated in
FIG. 56 comprises a tubular member, which may be generally
cylindrical in form, and which is configured to be received within
the receptacle of the apparatus. First end 16-6 of the aerosol
carrier 14-6 is for location to oppose the heater of the apparatus,
and second end 18-6 (and the region adjacent the second end 18-6)
is configured for insertion into a user's mouth.
[0617] FIG. 57 illustrates some internal components of the aerosol
carrier 14-6 and of the heater 24-6 of apparatus 12-6, in one
embodiment of the disclosure.
[0618] As described above, the aerosol carrier 14-6 comprises a
fluid-transfer element 34-6. At least part of the fluid-transfer
article 34-6 may be removable from the housing 32-6, to enable it
to be replaced. The fluid-transfer article 34-6 acts as a reservoir
for aerosol precursor and that aerosol precursor will be consumed
as the apparatus is used. Once sufficient aerosol precursor has
been consumed, the aerosol precursor will need to be replaced. It
may then be easiest to replace it by replacing the fluid-transfer
article 34-6, rather than trying to re-fill the fluid-transfer
article 34-6 with aerosol precursor while it is in the housing
32-6.
[0619] In the illustrated embodiments, the fluid-transfer article
34-6 has a first region 35-6 formed by layers 35a-6 and 35b-6, and
a second region 36-6. That second region 36-6 has a first part
being an upper layer 36a-6 which is formed by a plate with a
plurality of holes 37-6 therein, and a second part being a lower
layer formed by a second plate 36b-6 made of a porous material
which allows aerosol precursor to pass therethrough. In the
arrangement of FIG. 57, the plate 36a-6 with holes 37-6 therein is
in contact with the first region 35-6 of the fluid-transfer article
34-6, so that aerosol precursor may pass from that first region
35-6 directly into the holes 37-6, and through those holes to the
second plate 36b-6.
[0620] Since the second plate 36b-6 is porous, the aerosol
precursor will pass to the surface of the plate 36b-6 remote from
the first region 35-6 of the fluid-transfer article 34-6, which
surface acts as an activation surface 41-6 of the fluid-transfer
article 34-6. A heater is mounted so as to contact the activation
surface 41-6. When the heater 24-6 is activated, the heat which it
generates will be transferred to the activation surface 41-6.
[0621] Further components not shown in FIG. 57 comprise: an inlet
conduit, via which air can be drawn into the aerosol carrier 14-6;
an outlet conduit, via which an air stream entrained with aerosol
can be drawn from the aerosol carrier 14-6; a filter element; and a
reservoir for storing aerosol precursor material and for providing
the aerosol precursor material to the fluid-transfer article
34-6.
[0622] In FIG. 57, the aerosol carrier is shown as comprising the
fluid-transfer article 34-6 located within housing 32. The fluid
transfer article 34-6 comprises a first region 35-6 holding an
aerosol precursor. In one or more arrangements, the first region of
35 of the fluid transfer article 34-6 comprises a reservoir for
holding the aerosol precursor. The first region 35-6 can be the
sole reservoir of the aerosol carrier 14-6, or it can be arranged
in fluid communication with a separate reservoir, where aerosol
precursor is stored for supply to the first region 35-6. As shown
in FIG. 57, the first region 35-6 has a first layer 35a-6 and a
second layer 35b-6. The material forming the first layer 35a-6 of
the first region 35-6 comprises a porous structure, whose pore
diameter size varies between one end of the first layer 35a-6 and
another end of the first layer 35a-6. The pore diameter size may
increase from a first end remote from heater 24-6 (the upper end is
as shown in the figure) to a second end. The pore diameter size may
change in a step-wise manner (i.e., a first part with pores having
a diameter of first size, and a second part with pores having a
diameter of second, smaller size), or the change in pore size in
the first layer 35a-6 may be gradual rather than step-wise. This
configuration of pores having a decreasing diameter size can
provide a wicking effect, which can serve to draw fluid through the
first layer 35a-6, towards heater 24-6.
[0623] The first region 35-6 of the fluid transfer article 34-6 may
also comprise a second layer 35b-6. Aerosol precursor is drawn from
the first layer 35a-6 to the second layer 35b-6 by the wicking
effect of the material forming the first layer 35a-6. Thus, the
first layer 35a-6 is configured to transfer the aerosol precursor
to the second layer 35b-6 of the first region 35-6 of the
fluid-transfer article 34-6.
[0624] The second layer 35b-6 itself may comprise a porous
structure formed by a porous polymer material. It is then
preferable that the pore diameter size of the porous structure of
the second layer 35b-6 is smaller than the pore diameter size of
the immediately adjacent part of the first layer 35a-6. As
mentioned above, the porous polymer material may be a sintered
material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET).
[0625] However, as mentioned previously, in some embodiments it is
envisaged that the first region 35-6 of the fluid-transfer article
need not be of porous polymer material as described above. Instead,
the first region 35-6 of the fluid-transfer article 34-6 may take
the form of a simple tank having a cavity defining a hollow
reservoir to hold the aerosol precursor. In such embodiments it is
proposed that the plate 36a-6 with holes 37-6 therein will extend
across the bottom of the tank so that aerosol precursor held in the
tank will impinge directly on the plate 36a-6 and pass directly
from the tank defining the first region 35-6 of the fluid-transfer
article 34-6 into the holes 37-6 of the second region 36-6 of the
fluid-transfer article.
[0626] As illustrated in FIG. 57, the second plate 36b-6 of second
region 36-6 has a plurality of recesses 38-6 therein so that the
activation surface 41-6 is convoluted, with parts in contact with
the heater 24-6, and parts at the recesses 38-6 are spaced from the
heater 24-6 to form the air-flow pathways along the activation
surface 41-6, through which air can pass as it flows from the
apertures 20-6 to the second end 18-6. The recesses 38-6 form
channels for the air-flow pathways.
[0627] In FIG. 57, the recesses are rectangular in cross-section.
Other shapes are also possible, such as square, V-shaped, or curved
or arched.
[0628] As discussed above, the heater 24-6 transfers heat to the
activation surface 41-6 thereby releasing aerosol precursor which
has reached that activation surface 41-6 through the porous polymer
material (or hollow reservoir) of the first region 35-6, and
through the second region 36-6. That vapor and/or a mixture of
vapor and aerosol, may then pass into the air adjacent the
activation surface 41-6 and the heater 24-6. In particular, the
vapor or mixture will pass into the spaces (channels) formed by the
recesses 38-6, from the walls of those recesses. The sizes of the
recesses 38-6, and the sizes of the parts of the activation surface
41-6 in contact with the heater 24-6 are chosen so as to balance
the need for the heater 24-6 to heat the second part 36-6 of the
intermediate structure 36-6 to release vapor from the activation
surface 41-6, and the need for the recesses 38-6 to be large enough
to permit an adequate flow of air along the air-flow pathways.
[0629] There is thus a fluid-flow path for air (hereinafter
referred to as an air-flow pathway) along each of the channels
formed by the recesses 38-6, linking the apertures 20-6 and the
second end 18-6 of the aerosol carrier. When the user sucks or
inhales, air is drawn along the air-flow pathways, along the
activation surface 41-6 through the channels formed by the recesses
38-6.
[0630] One or more droplets of the aerosol precursor will be
released from the second plate 36b-6 and heated, to release vapor
or a mixture of aerosol and vapor into the air flowing in the
air-flow pathway or pathways. The vapor or mixture passes, as the
user sucks and inhales, to the second end 18-6.
[0631] As mentioned above, the second region 36-6 of the
fluid-transfer article 34-6 comprises a first plate 36a-6 and a
second plate 36b-6. The first plate 36a-6 may be a molded polymer
disc so that is then easy to form the holes 37-6 therein by molding
the holes 37-6 when the plate 36a-6 is itself molded. The holes
37-6 are sufficiently large that they do not act as a capillary,
but instead define non-capillary spaces in the second region 36-6.
Hence, aerosol precursor is able to pass from the first region 35-6
of the fluid-transfer article to the second region 36-6 in a
non-capillary manner, into the holes 37-6, and then pass through
the second plate 36b-6 to the heater or heaters 24-6. The holes
37-6 may be relatively large, so that they fill with aerosol
precursor when the apparatus is in use.
[0632] The second plate 36b-6 is made of a porous material which is
more heat-resistant than the material of the plate 36a-6, as it is
acted on directly by the heater 24-6. It may be fibrous, made from
e.g., ceramic fiber, glass fiber or carbon fiber. Alternatively, it
may be formed from a high-temperature porous material such as
porous glass or porous ceramic. Another possibility is that the
second plate 36b-6 may be of a porous polymer material, such as the
materials described previously with reference to the layers 35a-6
and 35b-6 of the first region 35-6, provided that the polymer
material is sufficiently resistant to the high temperatures to
which it will be subject due to the heater or heaters 24-6.
[0633] It is thought that the flow of air in the recesses 38-6
along the activation surface 41-6 and past the heater 24-6 will
have the effect of creating the lower air pressure adjacent the
activation surface 41-6 which will tend to draw liquid through the
porous second plate 36b-6 to the activation surface 41-6. Thus, the
transfer of aerosol precursor from the fluid-transfer article 34-6
is facilitated.
[0634] As mentioned above, the fluid-transfer article 34-6, formed
by the first and second regions 35-6 and 36-6 and any further
reservoir of aerosol precursor, forms the consumable part of the
apparatus, in the sense that it can readily be replaced to enable
the aerosol precursor to be replaced once it is consumed. The
heater 24-6 is not part of the consumable elements. Thus, the
housing 32-6 containing the fluid-transfer article 34-6 may be
separable from a housing 43-6 supporting the heater 24-6 along the
line B-B in FIG. 57. The further housing 43-6 may be integral with
the housing 26-6 containing the electrical energy supply 28-6. It
is for this reason that the heater 24-6 makes contact with, but is
not bonded to, the activation surface 41-6. The contact ensures the
most efficient heat transfer from the heater 24-6 to the second
plate 36b-6 to heat the activation surface 41-6 but the heater 24-6
must be separable from that activation surface 41-6 to allow
removal of the housing 32-6 from the further housing 43-6 when the
fluid-transfer article 34-6 has become depleted. The line B to B
may therefore correspond to the part of the activation surface 41-6
which contacts the heater 24-6.
[0635] In FIG. 57, the heater 24-6 may be a coil, mesh or foil
heater such as a radial or Clapton coil. Such a coil, mesh or foil
heater is preferred so that any restriction caused by the heater
24-6 on release of aerosol or vapor from the activation surface
41-6 is minimized.
[0636] In the illustrative examples of FIG. 57, the first layer
35a-6 of the first region 35-6 of the fluid-transfer article 34-6
is located at an "upstream" end of the fluid-transfer article 34-6
and the second plate 35b-6 of the second region 35b-6 is located at
a downstream" end of the fluid-transfer article 34-6. That is,
aerosol precursor is wicked, or is drawn, from the "upstream" end
of the fluid-transfer article 34-6 to the "downstream" end of the
fluid-transfer article 34-6 (as denoted by arrow A in FIG. 57).
[0637] In FIG. 57, the heater 24-6 contacts the parts of the second
plate 36b-6 between the recesses 38-6. It thus makes direct (though
unbonded) contact with parts of the activation surface 41-6. This
ensures good heat transfer from the heater 24-6 to the second plate
36b-6, hence heating the activation surface 41-6, both where the
activation surface 41-6 contacts the heater 24-6 and at the
recesses 38-6. It would be possible for the heater 24-6 to be
spaced from the second plate 36b-6, but this is not preferred, both
because the first transfer would be less efficient, and also
because there would then be some air flow between the heater 24-6
and the activation surface 41-6 not through the channels formed by
the recesses 38-6.
[0638] In the arrangements shown in FIG. 57, the ends of the
channels formed by the recesses 38-6 are on opposite sides of the
housing 32-6. FIGS. 58 and 59 show an alternative configuration, in
which the fluid-transfer article is annular, and both the first
region 35-6 and the second region 36-6 are then in the form of
annuli. In FIGS. 58 and 59, the structure of the fluid-transfer
article 34-6, including the first region 35-6 and the second region
36-6 may correspond generally to that shown in FIG. 57. The
internal structure of the first and second regions 35-6 and 36-6
may be the same as in FIG. 57, but are not illustrated in detail in
FIGS. 58 and 59 for simplicity. However, the air flow in the
apparatus is discussed in more detail below. Thus, FIGS. 58 and 59
illustrate an aerosol carrier 14-6 according to one or more
possible arrangements in more detail. FIG. 58 is a cross-section
side view illustration of the aerosol carrier 14-6 and FIG. 59 is a
perspective cross-section side view illustration of the aerosol
carrier 14-6.
[0639] As can be seen from FIGS. 58 and 59, the aerosol carrier
14-6 is generally tubular in form. The aerosol carrier 14-6
comprises housing 32-6, which defines the external walls of the
aerosol carrier 14-6 and which defines therein a chamber in which
are disposed the fluid-transfer article 34-6 (adjacent the first
end 16-6 of the aerosol carrier 14-6) and internal walls defining
the fluid communication pathway 48-6. Fluid communication pathway
48-6 defines a fluid pathway for an outgoing air stream from the
channels 40-6 to the second end 18-6 of the aerosol carrier 14-6.
In the examples illustrated in FIGS. 58 and 59, the fluid-transfer
article 34-6 is an annular shaped element located around the fluid
communication pathway 48-6. The housing 32-6 containing the
fluid-transfer article 34-6 is separable from the housing 43-6
supporting the heater 24-6.
[0640] In walls of the housing 43-6, there are provided inlet
apertures 50-6 to provide a fluid communication pathway for an
incoming air stream to reach the activation surface 41-6 of the
second region 36-6 of the fluid-transfer article 34-6.
[0641] In the illustrated example of FIGS. 58 and 59, the aerosol
carrier 14-6 further comprises a filter element 52-6. The filter
element 52-6 is located across the fluid communication pathway 48-6
such that an outgoing air stream passing through the fluid
communication pathway 48-6 passes through the filter element
52-6.
[0642] With reference to FIG. 59, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18-6 of the aerosol carrier
14-6, if configured as a mouthpiece), air is drawn into the carrier
through inlet apertures 50-6 extending through walls in the housing
32-6 of the aerosol carrier 14-6.
[0643] An incoming airstream 42a-6 from a first side of the aerosol
carrier 14-6 is directed to a first side of the second region 36-6
(e.g., via a gas communication pathway within the housing of the
carrier). An incoming air stream 42b-6 from a second side of the
aerosol carrier 14-6 is directed to a second side of the second
region 36-6 (e.g., via a gas communication pathway within the
housing of the carrier). When the incoming air stream 42a-6 from
the first side of the aerosol carrier 14-6 reaches the first side
of the second region 36-6, the incoming air stream 42a-6 from the
first side of the aerosol carrier 14-6 flows along the activation
surface 41-6 of the second region 36-6 through the recesses 38-6 in
the second plate 36b-6. Likewise, when the incoming air stream
42b-6 from the second side of the aerosol carrier 14-6 reaches the
second side of the second region 36-6, the incoming air stream
42b-6 from the second side of the aerosol carrier 14-6 flows along
the activation surface 41-6 of the second region 36-6, again
through the recesses in the second plate 36b-6. The air streams
from each side are denoted by dashed lines 44a-6 and 44b-6 in FIG.
60 As these air streams 44a-6 and 44b-6 flow, aerosol precursor on
the activation surface 41-6 of the second region 36-6 is entrained
in air streams 44a-6 and 44b-6.
[0644] In use, the heater 24-6 of the apparatus 12-6 raise a
temperature of the second plate 36b-6 of the second region 36-6 to
a sufficient temperature to release, or liberate, captive
substances (i.e., the aerosol precursor) to form a vapor and/or
aerosol, which is drawn downstream. As the air streams 44a-6 and
44b-6 continue their passages, more released aerosol precursor is
entrained within the air streams 44a-6 and 44b-6. When the air
streams 44a-6 and 44b-6 entrained with aerosol precursor meet at a
mouth of the outlet fluid communication pathway 48-6, they enter
the outlet fluid communication pathway 48-6 and continue until they
pass through filter element 52-6 and exit outlet fluid
communication pathway 48-6, either as a single outgoing air stream,
or as separate outgoing air streams 46-6 (as shown). The outgoing
air streams 46-6 are directed to an outlet, from where it can be
inhaled by the user directly (if the second end 18-6 of the aerosol
capsule 14-6 is configured as a mouthpiece), or via a mouthpiece.
The outgoing air streams 46-6 entrained with aerosol precursor are
directed to the outlet (e.g., via a gas communication pathway
within the housing of the carrier).
[0645] FIG. 60 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10-6.
[0646] As will be appreciated, in the arrangements described above,
the fluid-transfer article 34-6 is provided within a housing 32-6
of the aerosol carrier 14-6. In such arrangements, the housing of
the carrier 14-6 serves to protect the aerosol precursor-containing
fluid-transfer article 34-6, whilst also allowing the carrier 14-6
to be handled by a user without his/her fingers coming into contact
with the aerosol precursor liquid retained therein.
[0647] In any of the embodiments described above the second plate
36b-6 of the second region 36-6 may have a thickness of less than 5
mm. In other embodiments it may have a thickness of: less than 3.5
mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9
mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than
1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less
than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm,
less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4
mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.
[0648] Seventh Mode: An Aerosol-Generation Apparatus has a Heater
and a Fluid-Transfer Article for Holding an Aerosol Precursor
[0649] Aspects and embodiments of the seventh mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the seventh mode will
be apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0650] In general outline, one or more embodiments in accordance
with the present disclosure may provide a system for aerosol
delivery in which an aerosol carrier may be inserted into a
receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier. Another end, or another end portion, of the aerosol
carrier may protrude from the apparatus and can be inserted into
the mouth of a user for the inhalation of aerosol released from the
aerosol carrier cartridge during operation of the apparatus.
[0651] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
[0652] Referring now to FIG. 61, there is illustrated a perspective
view of an aerosol delivery system 10-7 comprising an aerosol
generation apparatus 12-7 operative to initiate and maintain
release of aerosol from a fluid-transfer article in an aerosol
carrier 14-7. In the arrangement of FIG. 61, the aerosol carrier
14-7 is shown with a first end 16-7 thereof and a portion of the
length of the aerosol carrier 14-7 located within a receptacle of
the apparatus 12-7. A remaining portion of the aerosol carrier 14-7
extends out of the receptacle. This remaining portion of the
aerosol carrier 14-7, terminating at a second end 18-7 of the
aerosol carrier, is configured for insertion into a user's mouth. A
vapor and/or aerosol is produced when a heater (not shown in FIG.
61) of the apparatus 12-7 heats a fluid-transfer article in the
aerosol carrier 14-7 to release a vapor and/or an aerosol, and this
can be delivered to the user, when the user sucks or inhales, via a
fluid passage in communication with an outlet of the aerosol
carrier 14-7 from the fluid-transfer article to the second end
18-7.
[0653] The device 12-7 also comprises air-intake apertures 20-7 in
the housing of the apparatus 12-7 to provide a passage for air to
be drawn into the interior of the apparatus 12-7 (when the user
sucks or inhales) for delivery to the first end 16-7 of the aerosol
carrier 14-7, so that the air can be drawn across an activation
surface of a fluid-transfer article located within a housing of the
aerosol carrier cartridge 14-7 during use. Optionally, these
apertures may be perforations in the housing of the apparatus
12-7.
[0654] A fluid-transfer article (not shown in FIG. 61, but
described hereinafter with reference to FIGS. 65, 66, 67, 68, 69,
70, and 71) is located within a housing of the aerosol carrier
14-7. The fluid-transfer article contains an aerosol precursor
material, which may include at least one of: nicotine; a nicotine
precursor material; a nicotine compound; and one or more
flavorings. The fluid-transfer article is located within the
housing of the aerosol carrier 14-7 to allow air drawn into the
aerosol carrier 14-7 at, or proximal, the first end 16-7 to flow
across an activation surface of the fluid-transfer article. As air
passes across the activation surface of the fluid-transfer article,
an aerosol may be entrained in the air stream from a substrate
forming the fluid-transfer article, e.g., via diffusion from the
substrate to the air stream and/or via vaporization of the aerosol
precursor material and release from the fluid-transfer article
under heating.
[0655] The substrate forming the fluid-transfer article 34-7
comprises a porous material where pores of the porous material
hold, contain, carry, or bear the aerosol precursor material. In
particular, the porous material of the fluid-transfer article may
be a polymeric wicking material such as, for example, a sintered
material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET). All such
materials may be described as heat resistant polymeric wicking
material in the context of the present disclosure.
[0656] The aerosol carrier 14-7 is removable from the apparatus
12-7 so that it may be disposed of when expired. After removal of a
used aerosol carrier 14-7, a replacement aerosol carrier 14-7 can
be inserted into the apparatus 12-7 to replace the used aerosol
carrier 14-7.
[0657] FIG. 62 is a cross-sectional side view illustration of a
part of apparatus 12-7 of the aerosol delivery system 10-7. The
apparatus 12-7 comprises a receptacle 22-7 in which is located a
portion of the aerosol carrier 14-7. In one or more optional
arrangements, the receptacle 22-7 may enclose the aerosol carrier
14-7. The apparatus 12-7 also comprise a heater 24-7, which opposes
an activation surface of the fluid-transfer article (not shown in
FIG. 62) of the aerosol carrier 14-7 when an aerosol carrier 14-7
is located within the receptacle 22-7.
[0658] Air flows into the apparatus 12-7 (in particular, into a
closed end of the receptacle 22-7) via air-intake apertures 20-7.
From the closed end of the receptacle 22-7, the air is drawn into
the aerosol carrier 14-7 (under the action of the user inhaling or
sucking on the second end 18-7) and expelled at the second end
18-7. As the airflows into the aerosol carrier 14-7, it passes
across the activation surface of the fluid-transfer article. Heat
from the heater 24-7, which opposes the activation surface of the
fluid-transfer article, causes vaporization of aerosol precursor
material at the activation surface of the fluid-transfer article
and an aerosol is created in the air flowing over the activation
surface. Thus, through the application of heat in the region of the
activation surface of the fluid-transfer article, an aerosol is
released, or liberated, from the fluid-transfer article, and is
drawn from the material of the aerosol carrier unit by the air
flowing across the activation surface and is transported in the air
flow to via outlet conduits (not shown in FIG. 62) in the housing
of the aerosol carrier 14-7 to the second end 18-7. The direction
of air flow is illustrated by arrows in FIG. 62.
[0659] To achieve release of the captive aerosol from the
fluid-transfer article, the fluid-transfer article of the aerosol
carrier 14-7 is heated by the heater 24-7. As a user sucks or
inhales on second end 18-7 of the aerosol carrier 14-7, the aerosol
released from the fluid-transfer article and entrained in the air
flowing across the activation surface of the fluid-transfer article
is drawn through the outlet conduits (not shown) in the housing of
the aerosol carrier 14-7 towards the second end 18-7 and onwards
into the user's mouth.
[0660] Turning now to FIG. 63, a cross-sectional side view of the
aerosol delivery system 10-7 is schematically illustrated showing
the features described above in relation to FIGS. 61 and 62 in more
detail.
[0661] As can be seen, apparatus 12-7 comprises a housing 26-7, in
which are located the receptacle 22-7 and heater 24-7. The housing
26-7 also contains control circuitry (not shown) operative by a
user, or upon detection of air and/or vapor being drawn into the
device 12-7 through air-intake apertures 20-7, i.e., when the user
sucks or inhales. Additionally, the housing 26-7 comprises an
electrical energy supply 28, for example a battery. Optionally, the
battery comprises a rechargeable lithium-ion battery. The housing
26-7 also comprises a coupling 30 for electrically (and optionally
mechanically) coupling the electrical energy supply 28 to control
circuitry (not shown) for powering and controlling operation of the
heater 24-7.
[0662] Responsive to activation of the control circuitry of
apparatus 12-7, the heater 24-7 heats the fluid-transfer article
(not shown in FIG. 63) of aerosol carrier 14-7. This heating
process initiates (and, through continued operation, maintains)
release of vapor and/or an aerosol from the activation surface of
the fluid-transfer article. The vapor and/or aerosol formed as a
result of the heating process is entrained into a stream of air
being drawn across the activation surface of the fluid-transfer
article (as the user sucks or inhales). The stream of air with the
entrained vapor and/or aerosol passes through the aerosol carrier
14-7 via outlet conduits (not shown) and exits the aerosol carrier
14-7 at second end 18-7 for delivery to the user. This process is
briefly described above in relation to FIG. 62, where arrows
schematically denote the flow of the air stream into the device
12-7 and through the aerosol carrier 14-7, and the flow of the air
stream with the entrained vapor and/or aerosol through the aerosol
carrier cartridge 14-7.
[0663] FIGS. 64 to 66 schematically illustrate the aerosol carrier
14-7 in more detail (and, in FIGS. 65 and 66, features within the
receptacle in more detail). FIG. 64 illustrates an exterior of the
aerosol carrier 14-7, FIG. 65 illustrates internal components of
the aerosol carrier 14-7 in an optional arrangement, and FIG. 66
illustrates internal components of the aerosol carrier 14-7 in
another optional arrangement.
[0664] FIG. 64 illustrates the exterior of the aerosol carrier
14-7, which comprises housing 32-7 for housing said fluid-transfer
article (not shown) and at least one other internal component. The
particular housing 32-7 illustrated in FIG. 64 comprises a tubular
member, which may be generally cylindrical in form, and which is
configured to be received within the receptacle of the apparatus.
First end 16-7 of the aerosol carrier 14-7 is for location to
oppose the heater of the apparatus, and second end 18-7 (and the
region adjacent the second end 18-7) is configured for insertion
into a user's mouth.
[0665] FIG. 65 illustrates some internal components of the aerosol
carrier 14-7 and of the heater 24-7 of apparatus 12-7.
[0666] As described above, the aerosol carrier 14-7 comprises a
fluid-transfer article 34-7. The aerosol carrier 14-7 optionally
may comprise a conduction element 36-7 (as shown in FIG. 65) being
part of the heater 24-7. In one or more arrangements, the aerosol
carrier 14-7 is located within the receptacle of the apparatus such
that the activation surface of the fluid-transfer article opposes
the heater of the apparatus and receives heat directly from the
heater of the apparatus. In an optional arrangement, such as
illustrated in FIG. 65 for example, the aerosol carrier 14-7
comprises a conduction element 36-7. When aerosol carrier 14-7 is
located within the receptacle of the apparatus such that an
activation surface 38-7 of the fluid-transfer article 34-7 is
located to oppose the heater 24-7 of the apparatus, the conduction
element 36-7 is disposed between the rest of the heater 24-7 and
the activation surface 38-7 of the fluid-transfer article 34-7.
Heat may be transferred to the activation surface via conduction
through conduction element 36-7 (i.e., application of heat to the
activation surface is indirect).
[0667] Further components not shown in FIGS. 65 and 66 (see FIGS.
69 and 70) comprise: an inlet conduit, via which air can be drawn
into the aerosol carrier 14-7; an outlet conduit, via which an air
stream entrained with aerosol can be drawn from the aerosol carrier
14-7; a filter element; and a reservoir for storing aerosol
precursor material and for providing the aerosol precursor material
to the fluid-transfer article 34-7.
[0668] In FIGS. 65 and 66, aerosol carrier is shown as comprising
the fluid-transfer article 34-7 located within housing 32-7. The
material forming the fluid transfer article 34-7 comprises a porous
structure, where pore diameter size varies between one end of the
fluid-transfer article 34-7 and another end of the fluid-transfer
article. In the illustrative examples of FIGS. 65 and 66, the pore
diameter size gradually decreases from a first end remote from
heater 24-7 (the upper end as shown in the figure) to a second end
proximal heater 24-7 heater 24-7 (the lower end as shown in the
figure). Although the figure illustrates the pore diameter size
changing in a step-wise manner from the first to the second end
(i.e., a first region with pores having a diameter of a first size,
a second region with pores having a diameter of a second, smaller
size, and a third region with pores having a diameter of a third,
yet smaller size), the change in pore size from the first end to
the second end may be gradual rather than step-wise. This
configuration of pores having a decreasing diameter size from the
first end and second end can provide a wicking effect, which can
serve to draw fluid from the first end to the second end of the
fluid-transfer article 34-7.
[0669] The fluid-transfer article 34-7 comprises a first region
34a-7 for holding an aerosol precursor. In one or more
arrangements, the first region 34a-7 of the fluid-transfer article
34-7 comprises a reservoir for holding the aerosol precursor. The
first region 34a-7 can be the sole reservoir of the aerosol carrier
14-7, or it can be arranged in fluid communication with a separate
reservoir, where aerosol precursor is stored for supply to the
first region 34a-7.
[0670] The fluid-transfer article 34-7 also comprises a second
region 34b-7. Aerosol precursor is drawn from the first region
34a-7 to the second region 34b-7 by the wicking effect of the
substrate material forming the fluid transfer article. Thus, the
first region 34a-7 is configured to transfer the aerosol precursor
to the second region 34b-7 of the article 34-7.
[0671] At the second end of fluid-transfer article 34-7, the
surface of the second region 34b-7 defines the activation surface
38-7, which is disposed opposite a surface for conveying heat to
the activation surface 38-7. In the illustrative examples of FIGS.
65 and 66, the opposing surface for conveying heat to the
activation surface 38-7 comprises a conduction element 36-7 which
is a part of the heater 24-7. The conduction element 36-7 is
located for thermal interaction with the rest of the heater 24-7
and is arranged to transfer heat from the rest of the heater 24-7
to the activation surface 38-7. As noted above, however, the
conduction element 36-7 may be absent in some arrangements, in
which case the activation surface 38-7 is disposed to receive heat
directly from heater 24-7.
[0672] The conduction element 36-7, if present, may comprise a thin
film of thermally conductive material, such as, for example, a
metal foil (for example, aluminum, brass, copper, gold, steel,
silver, or an alloy comprising anyone of the foregoing together
with thermally conductive plastics and/or ceramics).
[0673] The surface of the conduction element 36-7 is discontinuous
such that at least one channel 40-7 is formed between the
activation surface 38-7 and the conduction element 36-7 (or the
upper surface of the heater 24-7 is discontinuous in the case of
arrangements in which the conduction element 36-7 is absent). In
some arrangements, the discontinuities may be such that the surface
of the conduction element 36-7 or heater 24-7 itself is
undulating.
[0674] In the illustrative examples of FIGS. 65 and 66, the
conduction element 36-7 has a plurality of grooves or valleys
therein to form an undulating surface, the grooves or valleys being
disposed in a parallel arrangement in the conduction element 36-7.
Since it is the surface of the conduction element 36-7 closest to
the activation surface 38-7 which acts as the heating surface for
the aerosol precursor, those grooves or valleys can be said to be
in the heating surface. The grooves or valleys define a plurality
of channels 40-7, between the activation surface 38-7 and the
conduction element 36-7.
[0675] In the illustrative example of FIG. 65, the grooves or
valleys in the conduction element 36-7 provide alternating peaks
and troughs that give rise to a "saw-tooth" type profile. In one or
more optional arrangements, the surface of the conduction element
36-7 may comprise a "castellated" type profile (i.e., a "square
wave" type profile), for example, such as illustrated in the
example of FIG. 66. In one or more optional arrangements, the
surface of the conduction element 36-7 may comprise a "sinusoidal"
type profile. The profile may comprise a mixture of two or more of
the above profiles given as illustrative examples.
[0676] In the illustrative examples of FIGS. 65 and 66, the first
region 34a-7 of the fluid-transfer article 34-7 is located at an
"upstream" end of the fluid-transfer article 34-7 and the second
region 34b-7 is located at a downstream" end of the fluid-transfer
article 34-7. That is, aerosol precursor is wicked, or is drawn,
from the "upstream" end of the fluid-transfer article 34-7 to the
"downstream" end of the fluid-transfer article 34-7 (as denoted by
arrow A in FIG. 65).
[0677] The aerosol precursor is configured to release an aerosol
and/or vapor upon heating. Thus, when the activation surface 38-7
receives heat conveyed from heater 24-7, the aerosol precursor held
at the activation surface 38-7 is heated. The aerosol precursor,
which is captively held in material of the fluid-transfer article
at the activation surface 38-7 is released into an air stream
flowing through the channels 40-7 between the conduction element
36-7 and activation surface 38-7 (or between the heater 24-7 and
the activation surface 38-7) as an aerosol and/or vapor.
[0678] The shape and/or configuration of the conduction element
36-7 (or the upper surface of the heater 24-7 if no conduction
element is present) and the associated shape(s) and/or
configuration(s) of the one or more channels 40-7 formed between
the activation surface 38-7 and conduction element 36-7 (or between
the activation surface 38-7 and heater 24-7) permit air to flow
across the activation surface 38-7 (through the one or more
channels 40-7) and also increase the surface area of the activation
surface 38-7 of the fluid-transfer article 34-7 that is available
for contact with a flow of air across the activation surface
38-7.
[0679] FIGS. 67 and 68 show perspective view illustrations of the
fluid-transfer article 34-7 of the aerosol carrier and a heater
24-7 of the apparatus of the system for aerosol delivery. In
particular, these figures illustrate airflows across the activation
surface 38-7 when the apparatus is in use in a first arrangement of
the fluid-transfer article 34-7 (see FIG. 67), and in a second
arrangement of the fluid-transfer article 34-7 (see FIG. 68).
[0680] In the illustrated example of use of the apparatus
schematically illustrated in FIG. 67, when a user sucks on a
mouthpiece of the apparatus, air is drawn into the carrier through
inlet apertures (not shown) provided in a housing of the carrier.
An incoming air stream 42-7 is directed to the activation surface
38-7 of the fluid-transfer article 34-7 (e.g., via a fluid
communication pathway within the housing of the carrier). When the
incoming air stream 42-7 reaches a first side of the activation
surface 38-7, the incoming air stream 42-7 flows across the
activation surface 38-7 via the one or more channels 40-7 formed
between the activation surface 38-7 and the conduction element 36-7
(or between the activation surface 38-7 and heater 24-7). The air
stream flowing through the one or more channels 40-7 is denoted by
dashed line 44-7 in FIG. 67. As the air stream 44-7 flows through
the one or more channels 40-7, aerosol precursor at activation
surface 38-7, across which the air stream 44-7 flows, is released
from the activation surface 38-7 by heat conveyed to the activation
surface from the heater 24-7. Aerosol precursor released from the
activation surface 38-7 in this manner is then entrained in the air
stream 44-7 flowing through the one or more channels 40-7.
[0681] In use, the heater 24-7 of the apparatus 12-7 conveys heat
to the fluid transfer article 34-7 to raise the temperature of the
activation surface 38-7 to a sufficient temperature to release, or
liberate, captive substances (i.e., the aerosol precursor) held at
the activation surface 38-7 of the fluid-transfer article 34-7 to
form a vapor and/or aerosol, which is drawn downstream across the
activation surface 38-7 of the fluid-transfer article. As the air
stream 44-7 continues its passage in the one or more channels 40-7,
more released aerosol precursor is entrained within the air stream
44-7. When the air stream 44-7 entrained with aerosol precursor
exits the one or more channels 40-7 at a second side of the
activation surface 38-7, it is directed to an outlet, from where it
can be inhaled by the user via a mouthpiece. An outgoing air stream
46-7 entrained with aerosol precursor is directed to the outlet
(e.g., via a fluid communication pathway within the housing of the
carrier).
[0682] Therefore, operation of the apparatus will cause heat from
the heater 24-7 to be conveyed to the activation surface 38-7 of
the fluid-transfer article. At a sufficiently high temperature,
captive substances held at the activation surface 38-7 of the
fluid-transfer article 34-7 are released, or liberated, to form a
vapor and/or aerosol. Thus, when a user draws on a mouthpiece of
the apparatus, the released substances from the fluid-transfer
article are drawn away from the activation surface 38-7 (entrained
in a stream of air) and condense to form an aerosol that is drawn
through the gas communication pathway for delivery to an outlet,
which is in fluid communication with the mouthpiece.
[0683] As the aerosol precursor is released from the activation
surface 38-7, a wicking effect of the fluid-transfer article 34-7
causes aerosol precursor within the body of the fluid-transfer
article to migrate to the activation surface 38-7 to replace the
aerosol precursor released from the activation surface 38-7 into
air stream 44-7.
[0684] Operation of the heater 24-7 is controlled by control
circuitry (not shown), which is operable to actuate the heater 24-7
responsive to an actuation signal from a switch operable by a user
or configured to detect when the user draws air through a
mouthpiece of the apparatus by sucking or inhaling. In an optional
arrangement, the control circuitry operates to actuate the heater
24-7 with as little delay as possible from receipt of the actuation
signal from the switch, or detection of the user drawing air
through the mouthpiece. This may affect near instantaneous heating
of the activation surface 38-7 of the fluid-transfer article
34-7.
[0685] In the illustrated example of use of the apparatus
schematically illustrated in FIG. 68, rather than the case of FIG.
67 where air is drawn toward the activation surface 38-7 from one
side only (and exits from the one or more channels 40-7 at an
opposite side), a gas communication pathway for an incoming air
stream is configured to deliver the incoming air stream to the
activation surface 38-7 from both sides of the fluid-transfer
article, and thus from both ends of the channels 40-7 formed
therein. In such an arrangement, a gas communication pathway for an
outlet airstream may be provided through the body of the
fluid-transfer article 34-7. An outlet fluid communication pathway
for an outlet airstream in the illustrative example of FIG. 68 is
denoted by reference number 48-7.
[0686] Thus, in the illustrative example of FIG. 68, when a user
draws on a mouthpiece of the apparatus, air is drawn into the
carrier 14-7 through inlet apertures (not shown) provided in a
housing of the carrier. An incoming air stream 42-7a from a first
side is directed to a first side of the activation surface 38-7 of
the fluid-transfer article 34-7 (e.g., via a gas communication
pathway within the housing of the carrier 14-7). An incoming air
stream 42-7b from a second side is directed to a second side of the
activation surface 38-7 of the fluid-transfer article 34-7 (e.g.,
via a gas communication pathway within the housing of the carrier
14-7). When the incoming air stream 42-7a from the first side
reaches the first side of the activation surface 38-7, the incoming
air stream 42-7a flows across the activation surface 38-7 via the
one or more channels 40-7 formed between the activation surface
38-7 and the conduction element 36-7 (or between the activation
surface 38-7 and heater 24-7). Likewise, when the incoming air
stream 42-7b from the second side reaches the second side of the
activation surface 38-7, the incoming air stream 42-7b flows across
the activation surface 38-7 via the one or more channels 40-7
formed between the activation surface 38-7 and the conduction
element 36-7 (or between the activation surface 38-7 and heater
24-7). The air streams 42a-7, 42b-7 from each side flowing through
the one or more channels 40-7 are denoted by dashed lines 44a-7 and
44b-7 in FIG. 68.
[0687] As air streams 44a-7 and 44b-7 flow through the one or more
channels 40-7, aerosol precursor in the activation surface 38-7,
across which the air streams 44a-7 and 44b-7 flow, is released from
the activation surface 38-7 by heat conveyed to the activation
surface from the heater 24-7. Aerosol precursor released from the
activation surface 38-7 is entrained in air streams 44a-7 and 44b-7
flowing through the one or more channels 40-7. In use, the heater
24-7 of the apparatus 12-7 conveys heat to the fluid-transfer
article 34-7 to raise a temperature of the activation surface 38-7
to a sufficient temperature to release, or liberate, captive
substances (i.e., the aerosol precursor) held at the activation
surface 38-7 of the fluid-transfer article 34-7 to form a vapor
and/or aerosol, which is drawn downstream across the activation
surface 38-7 of the fluid-transfer article.
[0688] As the air streams 44a-7 and 44b-7 continue their passages
in the one or more channels 40-7, more released aerosol precursor
is entrained within the air streams 44a-7 and 44b-7. When the air
streams 44a-7 and 44b-7 entrained with aerosol precursor meet at a
mouth of the outlet fluid communication pathway 48-7, they enter
the outlet fluid communication pathway 48-7 and continue until they
exit outlet fluid communication pathway 48-7, either as a single
outgoing air stream 46-7 (as shown), or as separate outgoing air
streams. The outgoing air stream 46-7 is directed to an outlet,
from where it can be inhaled by the user via a mouthpiece. The
outgoing air stream 46-7 entrained with aerosol precursor is
directed to the outlet (e.g., via a gas communication pathway
within the housing of the carrier 14-7).
[0689] FIGS. 69 and 70 illustrate an aerosol carrier 14-7 according
to one or more possible arrangements in more detail. FIG. 69 is a
cross-section side view illustration of the aerosol carrier 14-7
and FIG. 70 is a perspective cross-section side view illustration
of the aerosol carrier 14-7 of FIG. 69.
[0690] As can be seen from FIGS. 69 and 70, the aerosol carrier
14-7 is generally tubular in form. The aerosol carrier 14-7
comprises housing 32-7, which defines the external walls of the
aerosol carrier 14-7 and which defines therein a chamber in which
are disposed the fluid-transfer article 34-7 (adjacent the first
end 16-7 of the aerosol carrier 14-7) and internal walls defining
the fluid communication pathway 48-7. Fluid communication pathway
48-7 defines a fluid pathway for an outgoing air stream from the
channels 40-7 to the second end 18-7 of the aerosol carrier 14-7.
In the examples illustrated in FIGS. 69 and 70, the fluid-transfer
article 34-7 is an annular shaped element located around the fluid
communication pathway 48-7. Note that, in FIGS. 69 and 70, the
channels 40-7 in the conduction element 36-7 extend radially and
the sectional views of FIGS. 69 and 70 are along the length of two
channels on opposite radial positions relative to the fluid
communication pathway 48-7 in the fluid-transfer article.
[0691] In walls of the housing 32-7, there are provided inlet
apertures 50-7 to provide a fluid communication pathway for an
incoming air stream to reach the fluid-transfer article 34-7, and
particularly the one or more channels 40-7 defined between the
activation surface of the fluid-transfer article 34-7 and the
conduction element 36-7 (or between the activation surface and the
15 heater).
[0692] In the illustrated example of FIGS. 69 and 70, the aerosol
carrier 14-7 further comprises a filter element 52-7. The filter
element 52-7 is located across the fluid communication pathway 48-7
such that an outgoing air stream passing through the fluid
communication pathway 48-7 passes through the filter element
52-7.
[0693] With reference to FIG. 70, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18-7 of the aerosol carrier
14-7, if configured as a mouthpiece), air is drawn into the carrier
through inlet apertures 50-7 extending through walls in the housing
32-7 of the aerosol carrier 14-7. An incoming air stream 42-7a from
a first side of the aerosol carrier 14-7 is directed to a first
side of the activation surface 38-7 of the fluid-transfer article
34-7 (e.g., via a gas communication pathway within the housing of
the carrier). An incoming air stream 42-7b from a second side of
the aerosol carrier 14-7 is directed to a second side of the
activation surface 38-7 of the fluid-transfer article 34-7 (e.g.,
via a gas communication pathway within the housing of the carrier).
When the incoming air stream 42-7a from the first side of the
aerosol carrier 14-7 reaches the first side of the activation
surface 38-7, the incoming air stream 42-7a from the first side of
the aerosol carrier 14-7 flows across the activation surface 38-7
via the one or more channels 40-7 formed between the activation
surface 38-7 and the conduction element 36-7 (or between the
activation surface 38-7 and heater 24-7). Likewise, when the
incoming air stream 42-7b from the second side of the aerosol
carrier 14-7 reaches the second side of the activation surface
38-7, the incoming air stream 42-7b from the second side of the
aerosol carrier 14-7 flows across the activation surface 38-7 via
the one or more channels 40-7 formed between the activation surface
38-7 and the conduction element 36-7 (or between the activation
surface 38-7 and heater 24-7). The air streams from each side
flowing through the one or more channels 40-7 are denoted by dashed
lines 44a-7 and 44b-7 in FIG. 68. As air streams 44a-7 and 44b-7
flow through the one or more channels 40-7, aerosol precursor in
the activation surface 38-7, across which the air streams 44a-7 and
44b-7 flow, is released from the activation surface 38-7 by heat
conveyed to the activation surface from the heater 24-7. Aerosol
precursor released from the activation surface 38-7 is entrained in
air streams 44a-7 and 44b-7 flowing through the one or more
channels 40-7.
[0694] In use, the heater 24-7 of the apparatus 12-7 conveys heat
to the activation surface 38-7 of the fluid-transfer article 34-7
to raise a temperature of the activation surface 38-7 to a
sufficient temperature to release, or liberate, captive substances
(i.e., the aerosol precursor) held at the activation surface 38-7
of the fluid-transfer article 34-7 to form a vapor and/or aerosol,
which is drawn downstream across the activation surface 38-7 of the
fluid-transfer article 34-7.
[0695] As the air streams 44a-7 and 44b-7 continue their passages
in the one or more channels 40-7, more released aerosol precursor
is entrained within the air streams 44a-7 and 44b-7. When the air
streams 44a-7 and 44b-7 entrained with aerosol precursor meet at a
mouth of the outlet fluid communication pathway 48-7, they enter
the outlet fluid communication pathway 48-7 and continue until they
pass through filter element 52-7 and exit outlet fluid
communication pathway 48-7, either as a single outgoing air stream,
or as separate outgoing air streams 46-7 (as shown). The outgoing
air streams 46-7 are directed to an outlet, from where it can be
inhaled by the user directly (if the second end 18-7 of the aerosol
capsule 14-7 is configured as a mouthpiece), or via a mouthpiece.
The outgoing air streams 46-7 entrained with aerosol precursor are
directed to the outlet (e.g., via a gas communication pathway
within the housing of the carrier).
[0696] When the user initially draws on a mouthpiece of the
apparatus (or one the second end 18-7 of the aerosol carrier 14-7,
if configured as a mouthpiece), this will cause an air column
located in the fluid communication pathway 48-7 to move towards the
outlet. In turn, this will draw air into the fluid communication
pathway from the one or more channels 40-7. This will cause a
pressure drop in the channels 40-7. To equalize the pressure in the
channels 40-7, air will be drawn into the aerosol carrier 14-7, and
thus into the channels 40-7 via the inlet apertures 50-7. During
the period of lower pressure in the one or more channels 40-7 when
the user begins to draw, aerosol precursor in the fluid-transfer
medium will be released into the channels from the activation
surface 38-7, because the aerosol precursor is drawn into the one
or more channels by way of the lower pressure. This effect is in
addition to the effect of releasing the aerosol precursor from the
activation surface 38-7 by way of heat conveyed from the heater.
The drawing of the aerosol precursor from the activation surface
38-7 by way of the user sucking on the mouthpiece of the apparatus
(or one the second end 18-7 of the aerosol carrier 14-7, if
configured as a mouthpiece) may produce a dragging effect on the
volumetric rate of flow experienced by the user during a suction
action, i.e., the user may have to suck harder to achieve a same
volumetric rate of flow. This effect may manifest itself as a
similar physical sensation experienced by the user as those
experienced from a traditional smoking or tobacco product.
[0697] FIG. 71 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10-7.
[0698] As will be appreciated, in the arrangements described above,
the fluid-transfer article 34-7 is provided within a housing 32-7
of the aerosol carrier 14-7. In such arrangements, the housing of
the carrier 14-7 serves to protect the aerosol precursor-containing
fluid-transfer article 34-7, whilst also allowing the carrier 14-7
to be handled by a user without his/her fingers coming into contact
with the aerosol precursor liquid retained therein. In such
arrangements, it will be appreciated that the carrier 14-7 has a
multi-part construction.
[0699] The second region 34b-7 of the fluid-transfer article may
have a thickness of less than 5 mm. In other embodiments it may
have a thickness of: less than 3.5 mm, less than 3 mm, less than
2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8 mm, less
than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4 mm,
less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than 1
mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less than
0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm, less
than 0.2 mm, or less than 0.1 mm.
[0700] There has been described in the foregoing one or more
proposals for an aerosol delivery system, and parts thereof, that
avoids or at least ameliorates problems of the prior art.
[0701] In one or more optional arrangements, a fluid-transfer
article 34-7 containing nicotine and/or nicotine compounds may be
substituted or supplemented with a fluid-transfer article
configured to provide a flavored vapor and/or aerosol upon heating
of the fluid-transfer article by the heater 24-7 of the apparatus
12-7. A precursor material for forming the flavored vapor and/or
aerosol upon heating is held within pores, spaces, channels and/or
conduits within the fluid-transfer article. The precursor material
may be extracted from a tobacco plant starting material using a
supercritical fluid extraction process. Optionally, the precursor
material is nicotine-free and comprises tobacco-flavors extracted
from the tobacco plant starting material. Further optionally, the
extracted nicotine-free precursor material (e.g., flavors only)
could have nicotine added thereto prior to loading of the precursor
material into the substrate of the carrier unit. Further
optionally, flavors and physiologically active material may be
extracted from plants other than tobacco plants.
[0702] Eighth Mode: An Aerosol-Generation Apparatus has a
Fluid-Transfer Article which Holds Aerosol Precursor and which
Transfers that Aerosol Precursor to an Activation Surface
[0703] Aspects and embodiments of the eighth mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the eighth mode will be
apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0704] In general outline, one or more embodiments of the eighth
mode in accordance with the present disclosure may provide a system
for aerosol delivery in which an aerosol carrier may be inserted
into a receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier.
[0705] Another end, or another end portion, of the aerosol carrier
may protrude from the apparatus and can be inserted into the mouth
of a user for the inhalation of aerosol released from the aerosol
carrier cartridge during operation of the apparatus.
[0706] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
[0707] Referring now to FIG. 72, there is illustrated a perspective
view of an aerosol delivery system 10-8 comprising an aerosol
generation apparatus 12-8 operative to initiate and maintain
release of aerosol from a fluid-transfer article in an aerosol
carrier 14-8. In the arrangement of FIG. 72, the aerosol carrier
14-8 is shown with a first end 16-8 thereof and a portion of the
length of the aerosol carrier 14-8 located within a receptacle of
the apparatus 12-8. A remaining portion of the aerosol carrier 14-8
extends out of the receptacle. This remaining portion of the
aerosol carrier 14-8, terminating at a second end 18-8 of the
aerosol carrier, is configured for insertion into a user's mouth. A
vapor and/or aerosol is produced when a heater (not shown in FIG.
72) of the apparatus 12-8 heats a fluid-transfer article in the
aerosol carrier 14-8 to release a vapor and/or an aerosol, and this
can be delivered to the user, when the user sucks or inhales, via a
fluid passage in communication with an outlet of the aerosol
carrier 14-8 from the fluid-transfer article to the second end
18-8.
[0708] The device 12-8 also comprises air-intake apertures 20-8 in
the housing of the apparatus 12-8 to provide a passage for air to
be drawn into the interior of the apparatus 12-8 (when the user
sucks or inhales) for delivery to the first end 16-8 of the aerosol
carrier 14-8, so that the air can be drawn across an activation
surface of a fluid-transfer article located within a housing of the
aerosol carrier cartridge 14-8 during use. Optionally, these
apertures may be perforations in the housing of the apparatus
12-8.
[0709] A fluid-transfer article (not shown in FIG. 72, but
described hereinafter with reference to FIGS. 76 to 78 is located
within a housing of the aerosol carrier 14-8. The fluid-transfer
article contains an aerosol precursor material, which may include
at least one of: nicotine; a nicotine precursor material; a
nicotine compound; and one or more flavorings. The fluid-transfer
article is located within the housing of the aerosol carrier 14-8
to allow air drawn into the aerosol carrier 14-8 at, or proximal,
the first end 16-8 to flow across an activation surface of the
fluid-transfer article. As air passes across the activation surface
of the fluid-transfer article, an aerosol may be entrained in the
air stream from a substrate forming the fluid-transfer article,
e.g., via diffusion from the substrate to the air stream and/or via
vaporization of the aerosol precursor material and release from the
fluid-transfer article under heating.
[0710] The substrate forming the fluid-transfer article 34-8 may at
least partly comprise a porous material where pores of the porous
material hold, contain, carry, or bear the aerosol precursor
material. In particular, the porous material of the fluid-transfer
article is a porous polymer material such as, for example, a
sintered material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET). All such
materials may be described as heat resistant polymeric wicking
material in the context of the present disclosure.
[0711] The aerosol carrier 14-8 is removable from the apparatus
12-8 so that it may be disposed of when expired. After removal of a
used aerosol carrier 14-8, a replacement aerosol carrier 14-8 can
be inserted into the apparatus 12-8 to replace the used aerosol
carrier 14-8.
[0712] FIG. 73 is a cross-sectional side view illustration of a
part of apparatus 12-8 of the aerosol delivery system 10-8. The
apparatus 12-8 comprises a receptacle 22-8 in which is located a
portion of the aerosol carrier 14-8. In one or more optional
arrangements, the receptacle 22-8 may enclose the aerosol carrier
14-8. The apparatus 12-8 also comprises a heater 24-8, which
opposes an activation surface of the fluid-transfer article (not
shown in FIG. 73) of the aerosol carrier 14-8 when an aerosol
carrier 14-8 is located within the receptacle 22-8.
[0713] Air flows into the apparatus 12-8 (in particular, into a
closed end of the receptacle 22-8) via air-intake apertures 20-8.
From the closed end of the receptacle 22-8, the air is drawn into
the aerosol carrier 14-8 (under the action of the user inhaling or
sucking on the second end 18-8) and expelled at the second end
18-8. As the air flows into the aerosol carrier 14-8, it passes
across the activation surface of the fluid-transfer article. Heat
from the heater 24-8, which acts on the activation surface of the
fluid-transfer article, causes vaporization of aerosol precursor
material at the activation surface of the fluid-transfer article
and an aerosol is created in the air flowing over the activation
surface. Thus, through the application of heat in the region of the
activation surface of the fluid-transfer article, an aerosol is
released, or liberated, from the fluid-transfer article, and is
drawn from the material of the aerosol carrier unit by the air
flowing across the activation surface and is transported in the air
flow to via outlet conduits (not shown in FIG. 73) in the housing
of the aerosol carrier 14-8 to the second end 18-8. The direction
of air flow is illustrated by arrows in FIG. 73.
[0714] To achieve release of the captive aerosol from the
fluid-transfer article, the fluid-transfer article of the aerosol
carrier 14-8 is heated by the heater 24-8. As a user sucks or
inhales on second end 18-8 of the aerosol carrier 14-8, the aerosol
released from the fluid-transfer article and entrained in the air
flowing across the activation surface of the fluid-transfer article
is drawn through the outlet conduits (not shown) in the housing of
the aerosol carrier 14-8 towards the second end 18-8 and onwards
into the user's mouth.
[0715] Turning now to FIG. 74, a cross-sectional side view of the
aerosol delivery system 10-8 is schematically illustrated showing
the features described above in relation to FIGS. 72 and 73 in more
detail. As can be seen, apparatus 12-8 comprises a housing 26-8, in
which are located the receptacle 22-8 and heater 24-8. The housing
26-8 also contains control circuitry (not shown) operative by a
user, or upon detection of air and/or vapor being drawn into the
device 12-8 through air-intake apertures 20-8, i.e., when the user
sucks or inhales. Additionally, the housing 26-8 comprises an
electrical energy supply 28-8, for example a battery. Optionally,
the battery comprises a rechargeable lithium-ion battery. The
housing 26-8 also comprises a coupling 30-8 for electrically (and
optionally mechanically) coupling the electrical energy supply 28-8
to control circuitry (not shown) for powering and controlling
operation of the heater 24-8.
[0716] Responsive to activation of the control circuitry of
apparatus 12-8, the heater 24-8 heats the fluid-transfer article
(not shown in FIG. 74) of aerosol carrier 14-8. This heating
process initiates (and, through continued operation, maintains)
release of vapor and/or an aerosol from the activation surface of
the fluid-transfer article. The vapor and/or aerosol formed as a
result of the heating process is entrained into a stream of air (as
the user sucks or inhales). The stream of air with the entrained
vapor and/or aerosol passes through the aerosol carrier 14-8 via
outlet conduits (not shown) and exits the aerosol carrier 14-8 at
second end 18-8 for delivery to the user. This process is briefly
described above in relation to FIG. 73, where arrows schematically
denote the flow of the air stream into the device 12-8 and through
the aerosol carrier 14-8, and the flow of the air stream with the
entrained vapor and/or aerosol through the aerosol carrier
cartridge 14-8.
[0717] FIGS. 75 to 77 schematically illustrate the aerosol carrier
14-8 in more detail (and, in FIG. 76, features within the
receptacle in more detail). FIG. 75 illustrates an exterior of the
aerosol carrier 14-8, and FIG. 76 illustrates internal components
of the aerosol carrier 14-8 in one optional configuration.
[0718] FIG. 75 illustrates the exterior of the aerosol carrier
14-8, which comprises housing 32-8 for housing said fluid-transfer
article (not shown) and at least one other internal component. The
particular housing 32-8 illustrated in FIG. 75 comprises a tubular
member, which may be generally cylindrical in form, and which is
configured to be received within the receptacle of the apparatus.
First end 16-8 of the aerosol carrier 14-8 is for location to
oppose the heater of the apparatus, and second end 18-8 (and the
region adjacent the second end 18-8) is configured for insertion
into a user's mouth.
[0719] FIG. 76 illustrates some internal components of the aerosol
carrier 14-8 and of the heater 24-8 of apparatus 12-8, in in one
embodiment of the disclosure.
[0720] As described above, the aerosol carrier 14-8 comprises a
fluid-transfer article 34-8. In one or more arrangements, the
aerosol carrier 14-8 is located within the receptacle of the
apparatus such that the activation surface of the fluid-transfer
article is in contact with the heater 24-8 of the apparatus and
receives heat directly from the heater 24-8 of the apparatus.
[0721] Further components not shown in FIG. 76 comprise: an inlet
conduit, via which air can be drawn into the aerosol carrier 14-8;
an outlet conduit, via which an air stream entrained with aerosol
can be drawn from the aerosol carrier 14-8; a filter element; and a
reservoir for storing aerosol precursor material and for providing
the aerosol precursor material to the fluid-transfer article
34-8.
[0722] In FIG. 76, the aerosol carrier is shown as comprising the
fluid-transfer article 34-8 located within housing 32-8. The fluid
transfer article 34-8 comprises a first region 34a-8 holding an
aerosol precursor. In one or more arrangements, the first region of
34a of the fluid transfer article 34-8 comprises a reservoir for
holding the aerosol precursor. The first region 34a-8 can be the
sole reservoir of the aerosol carrier 14-8, or it can be arranged
in fluid communication with a separate reservoir, where aerosol
precursor is stored for supply to the first region 34a-8. As shown
in FIG. 76, the material forming the first region of 34a comprises
a porous structure, whose pore diameter size varies between one end
of the first region 34a-8 and another end of the first region
34a-8. The pore diameter size decreases from a first end remote
from heater 24-8 (the upper end is as shown in the figure) to a
second end. The pore diameter size may change in a step-wise manner
(i.e., a first part with pores having a diameter of first size, and
a second part with pores having a diameter of second, smaller
size), or the change in pore size in the first region 34a-8 may be
gradual rather than step-wise. This configuration of pores having a
decreasing diameter size can provide a wicking effect, which can
serve to draw fluid through the first region 34a-8, towards heater
24-8.
[0723] Alternatively, the first region 34a-8 may be a simple liquid
reservoir, void except when filled with liquid, and the porous
material is not used.
[0724] The fluid transfer article 34-8 also comprises a second
region 34b-8. Aerosol precursor is drawn from the first region of
34a through the second region 34b-8 by the wicking effect of the
material forming the second region 34b-8. Thus, the second region
34b-8 is configured to transfer the aerosol precursor to an
activation surface 35-8 of the article 34-8.
[0725] The second region 34b-8 itself may comprise a porous
structure formed by a porous polymer material. It is then
preferable that the pore diameter size of the porous structure of
the second region 34b-8 is smaller than the pore diameter size of
the immediately adjacent part of the first region 34a-8. As
mentioned above, the porous polymer material may be a sintered
material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET).
[0726] Other materials may be used to form the second region 34b-8.
For example, it may be formed of fibrous material such as glass or
ceramic fiber material, or from sintered glass, ceramic or carbon,
or from carbon or glass foam.
[0727] In FIG. 76, the second region 34b-8 terminates in the
activation surface 35-8 which is in abutting unbonded contact with
the heater 24-8. In FIG. 76, the heater 24-8 comprises a plurality
of heater elements, with gaps forming spacing between the heater
elements. When the heater 24-8 is activated, aerosol precursor at
the activation surface 35-8 is released as vapor and/or a mixture
of vapor and aerosol, which may then pass through the gaps in the
heater.
[0728] FIG. 76 also illustrates an opening 38-8 in a housing 43-8,
which opening 38-8 is in communication with the air-intake
apertures 20-8. A further opening 39-8 communicates with a duct
40-8 within the housing 32-8, which duct 40-8 communicates with the
second end 18-8. The housing 43-8 supports the heater 24-8. The
housing 43-8 may be integral with the housing 26-8 containing the
electrical energy supply 28-8.
[0729] There is thus a fluid-flow path for air (hereinafter
referred to as an air-flow pathway) between openings 38-8 and 39-8,
linking the apertures 20-8 and the second end 18-8 of the aerosol
carrier. When the user sucks or inhales, air is drawn along the
air-flow pathway, along the activation surface 35-8 of the second
region 34b-8.
[0730] One or more droplets of the aerosol precursor will form at
the activation surface 35-8 and be heated, to release vapor or a
mixture of aerosol and vapor from the activation surface 35-8, and
through the gaps in the heater 24-8, into the air flowing in the
air-flow pathway between the openings 38-8, 39-8. The vapor or
mixture passes, as the user sucks and inhales, to the second end
18-8.
[0731] As mentioned above, the heater 24-8 is not bonded to the
activation surface 35-8, but is separable therefrom. When in the
position shown in FIG. 76, the activation surface makes contact
with the heater 24-8, to be directly heated. To assist in this, the
activation surface 35-8 is preferably planar. However, the housing
32-8 containing the fluid-transfer article 34-8 is separable from
the housing 43-8 which supports the heater 24-8, along the line B-B
in FIG. 76. This allows the carrier 14-8 including the housing 32-8
and the fluid-transfer article 34-8 to be removed from the rest of
the apparatus, without removing the heater 24-8.
[0732] FIG. 76 also illustrates a plate 33-8 of housing 43-8, which
plate 33-8 is spaced from the activation surface 35-8 and forms a
boundary of the air-flow pathway along the activation surface
35-8.
[0733] In the illustrative examples of FIG. 76, the first region
34a-8 of the fluid-transfer article 34-8 is located at an
"upstream" end of the fluid-transfer article 34-8 and the second
region 34b-8 is located at a downstream" end of the fluid-transfer
article 34-8. That is, aerosol precursor is wicked, or is drawn,
from the "upstream" end of the fluid-transfer article 34-8 to the
"downstream" end of the fluid-transfer article 34-8 (as denoted by
arrow A in FIG. 76).
[0734] When the heater 24-8 is active, heated aerosol precursor in
the form of vapor and/or vapor/aerosol mixture must pass into the
air-flow pathway between the openings 38-8 and 39-8. It must
therefore pass through the heater 24-8, which is why there need to
be gaps in the heater 24-8 as mentioned previously. The relative
proportion of the activation surface 35-8 covered by elements of
the heater 24-8 compared with the area open to the air-flow pathway
due to the gaps in the heater, will represent a balance between the
heating effect needed to vaporize the aerosol precursor, and the
movement of that vapor into the air-flow pathway. The heater 24-8
may thus be a mesh heater, with the spaces in the mesh forming the
gaps referred to previously. Alternatively, the heater may be a
foil heater, provided that the foil does not cover all of the
activation surface 35-8. Other heating configurations may be
possible.
[0735] In the arrangement shown in FIG. 76, the apertures 38-8,
39-8 are on opposite sides of the housing 32-8. FIGS. 77 and 78
show an alternative configuration, in which the fluid-transfer
article is annular, and the second part 34b-8 is then in the form
of annular diaphragm. In FIGS. 77 and 78, the arrangement of the
fluid-transfer article 34-8 and heater 24-8 may be generally the
same as in FIG. 76, albeit with an annular construction. The heater
24-8 is not illustrated in FIGS. 77 and 78, to enable the air flow
and the apparatus to be illustrated clearly. The parts which are
similar to those in FIG. 76 are indicated by the same reference
numerals. Thus, FIGS. 77 and 78 illustrate an aerosol carrier 14-8
according to one or more possible arrangements in more detail.
[0736] As can be seen from FIGS. 77 and 78, the aerosol carrier
14-8 is generally tubular in form. The aerosol carrier 14-8
comprises housing 32-8, which defines the external walls of the
aerosol carrier 14-8 and which defines therein a chamber in which
are disposed the fluid-transfer article 34-8 (adjacent the first
end 16-8 of the aerosol carrier 14-8) and internal walls defining
the fluid communication pathway 48-8. Fluid communication pathway
48-8 defines a fluid pathway for an outgoing air stream from the
channels 40-8 to the second end 18-8 of the aerosol carrier 14-8.
In the examples illustrated in FIGS. 77 and 78, the fluid-transfer
article 34-8 is an annular shaped element located around the fluid
communication pathway 48-8.
[0737] In walls of the housing 43-8 supporting the heater 24-8,
there are provided inlet apertures 50-8 to provide a fluid
communication pathway for an incoming air stream to reach the
fluid-transfer article 34-8, and in particular the air-flow pathway
defined between the activation surface of the fluid-transfer
article 34-8 and the plate 33-8.
[0738] In the illustrated example of FIGS. 77 and 78, the aerosol
carrier 14-8 further comprises a filter element 52-8. The filter
element 52-8 is located across the fluid communication pathway 48-8
such that an outgoing air stream passing through the fluid
communication pathway 48-8 passes through the filter element
52-8.
[0739] With reference to FIG. 77, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18-8 of the aerosol carrier
14-8, if configured as a mouthpiece), air is drawn into the carrier
through inlet apertures 50-8 extending through walls in the housing
43-8.
[0740] An incoming airstream 42a-8 from a first side of the aerosol
carrier 14-8 is directed to a first side of the second part 34b-8
of the fluid-transfer article 34-8 (e.g., via a gas communication
pathway within the housing of the carrier). An incoming air stream
42b-8 from a second side of the aerosol carrier 14-8 is directed to
a second side of the second part 34a-8 of the fluid-transfer
article 34-8 (e.g., via a gas communication pathway within the
housing of the carrier). When the incoming air stream 42a-8 from
the first side of the aerosol carrier 14-8 reaches the first side
of the second part 34b-8, the incoming air stream 42a-8 from the
first side of the aerosol carrier 14-8 flows between the second
part 34b-8 and the plate 33-8. Likewise, when the incoming air
stream 42b-8 from the second side of the aerosol carrier 14-8
reaches the second side of the second part 34a-8, the incoming air
stream 42b-8 from the second side of the aerosol carrier 14-8 flows
between the second part 34a-8 and the plate 33-8. The air streams
from each side are denoted by dashed lines 44a-8 and 44b-8 in FIG.
79 As these air streams 44a-8 and 44b-8 flow, aerosol precursor on
the activation surface 35-8 is entrained in air streams 44a-8 and
44b-8.
[0741] In use, the heater 24-8 of the apparatus is operable to
raise a temperature of the activation surface 35-8 to a sufficient
temperature to release, or liberate, captive substances (i.e., the
aerosol precursor) to form a vapor and/or aerosol, which is drawn
downstream. As the air streams 44a-8 and 44b-8 continue their
passages, more released aerosol precursor is entrained within the
air streams 44a-8 and 44b-8. When the air streams 44a-8 and 44b-8
entrained with aerosol precursor meet at a mouth of the outlet
fluid communication pathway 48-8, they enter the outlet fluid
communication pathway 48-8 and continue until they pass through
filter element 52-8 and exit outlet fluid communication pathway
48-8, either as a single outgoing air stream, or as separate
outgoing air streams 46-8 (as shown). The outgoing air streams 46-8
are directed to an outlet, from where it can be inhaled by the user
directly (if the second end 18-8 of the aerosol capsule 14-8 is
configured as a mouthpiece), or via a mouthpiece. The outgoing air
streams 46-8 entrained with aerosol precursor are directed to the
outlet (e.g., via a gas communication pathway within the housing of
the carrier).
[0742] In any of the embodiments described above the second part
34b-8 may have a thickness of less than 5 mm. In other embodiments
it may have a thickness of: less than 3.5 mm, less than 3 mm, less
than 2.5 mm, less than 2 mm, less than 1.9 mm, less than 1.8 mm,
less than 1.7 mm, less than 1.6 mm, less than 1.5 mm, less than 1.4
mm, less than 1.3 mm, less than 1.2 mm, less than 1.1 mm, less than
1 mm, less than 0.9 mm, less than 0.8 mm, less than 0.7 mm, less
than 0.6 mm, less than 0.5 mm, less than 0.4 mm, less than 0.3 mm,
less than 0.2 mm, or less than 0.1 mm.
[0743] FIG. 79 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10-8.
[0744] As will be appreciated, in the arrangements of the eighth
mode described above, the fluid-transfer article 34-8 is provided
within a housing 32-8 of the aerosol carrier 14-8. In such
arrangements, the housing of the carrier 14-8 serves to protect the
aerosol precursor-containing fluid-transfer article 34-8, whilst
also allowing the carrier 14-8 to be handled by a user without
his/her fingers coming into contact with the aerosol precursor
liquid retained therein.
[0745] Ninth Mode: An Aerosol Generation Apparatus has a
Fluid-Transfer Article with a First Region which Holds an Aerosol
Precursor
[0746] Aspects and embodiments of the ninth mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the ninth mode will be
apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0747] In general outline, one or more embodiments of the ninth
mode in accordance with the present disclosure may provide a system
for aerosol delivery in which an aerosol carrier may be inserted
into a receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier. Another end, or another end portion, of the aerosol
carrier may protrude from the apparatus and can be inserted into
the mouth of a user for the inhalation of aerosol released from the
aerosol carrier cartridge during operation of the apparatus.
[0748] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
[0749] Referring now to FIG. 79, there is illustrated a perspective
view of an aerosol delivery system 10-9 comprising an aerosol
generation apparatus 12-9 operative to initiate and maintain
release of aerosol from a fluid-transfer article in an aerosol
carrier 14-9. In the arrangement of FIG. 79, the aerosol carrier
14-9 is shown with a first end 16-9 thereof and a portion of the
length of the aerosol carrier 14-9 located within a receptacle of
the apparatus 12-9. A remaining portion of the aerosol carrier 14-9
extends out of the receptacle. This remaining portion of the
aerosol carrier 14-9, terminating at a second end 18-9 of the
aerosol carrier, is configured for insertion into a user's mouth. A
vapor and/or aerosol is produced when a heater (not shown in FIG.
79) of the apparatus 12-9 heats a fluid-transfer article in the
aerosol carrier 14-9 to release a vapor and/or an aerosol, and this
can be delivered to the user, when the user sucks or inhales, via a
fluid passage in communication with an outlet of the aerosol
carrier 14-9 from the fluid-transfer article to the second end
18-9.
[0750] The device 12-9 also comprises air-intake apertures 20-9 in
the housing of the apparatus 12-9 to provide a passage for air to
be drawn into the interior of the apparatus 12-9 (when the user
sucks or inhales) for delivery to the first end 16-9 of the aerosol
carrier 14-9, so that the air can be drawn across an activation
surface of a fluid-transfer article located within a housing of the
aerosol carrier cartridge 14-9 during use. Optionally, these
apertures may be perforations in the housing of the apparatus
12-9.
[0751] A fluid-transfer article 34-9 (not shown in FIG. 79, but
described hereinafter with reference to FIGS. 83 to 86 is located
within a housing of the aerosol carrier 14-9. The fluid-transfer
article 34-9 contains an aerosol precursor material, which may
include at least one of: nicotine; a nicotine precursor material; a
nicotine compound; and one or more flavorings. The fluid-transfer
article 34-9 is located within the housing of the aerosol carrier
14-9 to allow air drawn into the aerosol carrier 14-9 at, or
proximal, the first end 16-9, and has first and second regions, as
will be described.
[0752] The first region of the fluid-transfer article 34-9 may
comprise a substrate of porous material where pores of the porous
material hold, contain, carry, or bear the aerosol precursor
material. In particular, the porous material of the fluid-transfer
article may be a porous polymer material such as, for example, a
sintered material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET). All such
materials may be described as heat resistant polymeric wicking
material in the context of the present disclosure.
[0753] Alternatively, in some embodiments it is envisaged that the
first region of the fluid-transfer article 34-9 may take the form
of a simple tank having a cavity defining a hollow reservoir to
hold the aerosol precursor.
[0754] The aerosol carrier 14-9 is removable from the apparatus
12-9 so that it may be disposed of when expired. After removal of a
used aerosol carrier 14-9, a replacement aerosol carrier 14-9 can
be inserted into the apparatus 12-9 to replace the used aerosol
carrier 14-9.
[0755] FIG. 80 is a cross-sectional side view illustration of a
part of apparatus 12-9 of the aerosol delivery system 10-9. The
apparatus 12-9 comprises a receptacle 22-9 in which is located a
portion of the aerosol carrier 14-9. In one or more optional
arrangements, the receptacle 22-9 may enclose the aerosol carrier
14-9. The apparatus 12-9 also comprises a heater 24-9, which is in
contact with an activation surface of the fluid-transfer article
34-9 when an aerosol carrier 14-9 is located within the receptacle
22-9. Optional configurations of the heater 24-9 will be discussed
later.
[0756] Air flows into the apparatus 12-9 (in particular, into a
closed end of the receptacle 22-9) via air-intake apertures 20-9.
From the closed end of the receptacle 22-9, the air is drawn into
the aerosol carrier 14-9 (under the action of the user inhaling or
sucking on the second end 18-9) and expelled at the second end
18-9. As the air flows into the aerosol carrier 14-9, it passes
across the activation surface. Heat from the heater 24-9, which is
in contact with the activation surface of the fluid-transfer
article 34-9, causes vaporization of aerosol precursor material at
the activation surface of the fluid-transfer article 34-9 and an
aerosol is created in the air flowing over the activation surface.
Thus, through the application of heat to the activation surface, an
aerosol is released, or liberated, from the fluid-transfer article,
and is drawn from the material of the aerosol carrier unit by the
air flowing across the activation surface and is transported in the
air flow to via outlet conduits (not shown in FIG. 80) in the
housing of the aerosol carrier 14-9 to the second end 18-9. The
direction of airflow is illustrated by arrows in FIG. 80.
[0757] To achieve release of the captive aerosol from the
fluid-transfer article, the activation surface of the
fluid-transfer article 34-9 is heated by the heater 24-9. As a user
sucks or inhales on second end 18-9 of the aerosol carrier 14-9,
the aerosol released from the fluid-transfer article and entrained
in the air flowing across the activation surface is drawn through
the outlet conduits (not shown) in the housing of the aerosol
carrier 14-9 towards the second end 18-9 and onwards into the
user's mouth.
[0758] Turning now to FIG. 81, a cross-sectional side view of the
aerosol delivery system 10-9 is schematically illustrated showing
the features described above in relation to FIGS. 79 and 80 in more
detail. As can be seen, apparatus 12-9 comprises a housing 26-9, in
which is located the receptacle 22-9. The housing 26-9 also
contains control circuitry (not shown) operative by a user, or upon
detection of air and/or vapor being drawn into the device 12-9
through air-intake apertures 20-9, i.e., when the user sucks or
inhales. Additionally, the housing 26-9 comprises an electrical
energy supply 28-9, for example a battery. Optionally, the battery
comprises a rechargeable lithium-ion battery. The housing 26-9 also
comprises a coupling 30-9 for electrically (and optionally
mechanically) coupling the electrical energy supply 28-9 to control
circuitry (not shown) for powering and controlling operation of the
heater 24-9.
[0759] Responsive to activation of the control circuitry of
apparatus 12-9, the heater 24-9 heats the activation surface of the
fluid-transfer article 34-9 (not shown in FIG. 81). This heating
process initiates (and, through continued operation, maintains)
release of vapor and/or an aerosol from the activation surface of
the fluid-transfer article 34-9. The vapor and/or aerosol formed as
a result of the heating process is entrained into a stream of air
being drawn across the activation surface of the fluid-transfer
article 34-9 (as the user sucks or inhales). The stream of air with
the entrained vapor and/or aerosol passes through the aerosol
carrier 14-9 via outlet conduits (not shown) and exits the aerosol
carrier 14-9 at second end 18-9 for delivery to the user. This
process is briefly described above in relation to FIG. 80, where
arrows schematically denote the flow of the air stream into the
device 12-9 and through the aerosol carrier 14-9, and the flow of
the air stream with the entrained vapor and/or aerosol through the
aerosol carrier cartridge 14-9.
[0760] FIGS. 82 to 84 schematically illustrate the aerosol carrier
14-9 in more detail (and, in FIGS. 83 and 84, features within the
receptacle in more detail). FIG. 82 illustrates an exterior of the
aerosol carrier 14-9, FIG. 83 illustrates internal components of
the aerosol carrier 14-9 in one optional configuration, and FIG. 84
illustrates internal components of the aerosol carrier 14-9 in
another optional configuration.
[0761] FIG. 82 illustrates the exterior of the aerosol carrier
14-9, which comprises housing 32-9 for housing said fluid-transfer
article (not shown). The particular housing 32-9 illustrated in
FIG. 82 comprises a tubular member, which may be generally
cylindrical in form, and which is configured to be received within
the receptacle of the apparatus. First end 16-9 of the aerosol
carrier 14-9 is for location to oppose the heater of the apparatus,
and second end 18-9 (and the region adjacent the second end 18-9)
is configured for insertion into a user's mouth.
[0762] FIG. 83 illustrates some internal components of the aerosol
carrier 14-9 and of the heater 24-9 of apparatus 12-9, in one
embodiment of the disclosure.
[0763] As described above, the aerosol carrier 14-9 comprises a
fluid-transfer element 34-9. At least part of the fluid-transfer
article 34-9 may be removable from the housing 32-9, to enable it
to be replaced. The fluid-transfer article 34-9 acts as a reservoir
for aerosol precursor and that aerosol precursor will be consumed
as the apparatus is used. Once sufficient aerosol precursor has
been consumed, the aerosol precursor will need to be replaced. It
may then be easiest to replace it by replacing the fluid-transfer
article 34-9, rather than trying to re-fill the fluid-transfer
article 34-9 with aerosol precursor while it is in the housing
32-9.
[0764] In the illustrated embodiments, the fluid-transfer article
34-9 has a first region 35-9 formed by layers 35a-9 and 35b-9, and
a second region 36-9. That second region 36-9 has a first part
being an upper layer 36a-9 which is formed by a plate with a
plurality of holes 37-9 therein, and a second part being a lower
layer formed by a second plate 36b-9 made of a porous material
which allows aerosol precursor to pass therethrough. In the
arrangement of FIG. 83, the plate 36a-9 with holes 37-9 therein is
in contact with the first region 35-9 of the fluid-transfer article
34-9, so that aerosol precursor may pass from that first region
35-9 directly into the holes 37-9, and through those holes to the
second plate 36b-9.
[0765] Since the second plate 36b-9 is porous, the aerosol
precursor will pass to the surface of the plate 36b-9 remote from
the first region 35-9 of the fluid-transfer article 34-9, which
surface acts as an activation surface 41-9 of the fluid-transfer
article 34-9. One or more heaters 24-9 are mounted on the
activation surface 41-9. When the heater or heaters 24-9 are
activated, the heat which they generate will be transferred to the
activation surface 41-9.
[0766] Further components not shown in FIG. 83 comprise: an inlet
conduit, via which air can be drawn into the aerosol carrier 14-9;
an outlet conduit, via which an air stream entrained with aerosol
can be drawn from the aerosol carrier 14-9; a filter element; and a
reservoir for storing aerosol precursor material and for providing
the aerosol precursor material to the fluid-transfer article
34-9.
[0767] In FIG. 83, the aerosol carrier is shown as comprising the
fluid-transfer article 34-9 located within housing 32-9. The fluid
transfer article 34-9 comprises a first region 35-9 holding an
aerosol precursor. In one or more arrangements, the first region of
35 of the fluid transfer article 34-9 comprises a reservoir for
holding the aerosol precursor.
[0768] The first region 35-9 can be the sole reservoir of the
aerosol carrier 14-9, or it can be arranged in fluid communication
with a separate reservoir, where aerosol precursor is stored for
supply to the first region 35-9. As shown in FIG. 83, the first
region 35-9 has a first layer 35a-9 and a second layer 35b-9. The
material forming the first layer 35a-9 of the first region 35-9
comprises a porous structure, whose pore diameter size varies
between one end of the first layer 35a-9 and another end of the
first layer 35a-9. The pore diameter size may increase from a first
end remote from heater or heaters 24-9 (the upper end is as shown
in the figure) to a second end. The pore diameter size may change
in a step-wise manner (i.e., a first part with pores having a
diameter of first size, and a second part with pores having a
diameter of second, smaller size), or the change in pore size in
the first layer 35a-9 may be gradual rather than step-wise. This
configuration of pores having a decreasing diameter size can
provide a wicking effect, which can serve to draw fluid through the
first layer 35a-9, towards heater or heaters 24-9.
[0769] The first region 35-9 of the fluid transfer article 34-9 may
also comprise a second layer 35b-9. Aerosol precursor is drawn from
the first layer 35a-9 to the second layer 35b-9 by the wicking
effect of the material forming the first layer 35a-9. Thus, the
first layer 35a-9 is configured to transfer the aerosol precursor
to the second layer 35b-9 of the first region 35-9 of the
fluid-transfer article 34-9.
[0770] The second layer 35b-9 itself may comprise a porous
structure formed by a porous polymer material. It is then
preferable that the pore diameter size of the porous structure of
the second layer 35b-9 is smaller than the pore diameter size of
the immediately adjacent part of the first layer 35a-9. As
mentioned above, the porous polymer material may be a sintered
material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET).
[0771] However, as mentioned previously, in some embodiments it is
envisaged that the first region 35-9 of the fluid-transfer article
need not be of porous polymer material as described above. Instead,
the first region 35-9 of the fluid-transfer article 34-9 may take
the form of a simple tank having a cavity defining a hollow
reservoir to hold the aerosol precursor. In such embodiments it is
proposed that the plate 36a-9 with holes 37-9 therein will extend
across the bottom of the tank so that aerosol precursor held in the
tank will impinge directly on the plate 36a-9 and pass directly
from the tank defining the first region 35-9 of the fluid-transfer
article 34-9 into the holes 37-9 of the second region 36-9 of the
fluid-transfer article.
[0772] As discussed above, the heater or heaters 24-9 transfer heat
to the activation surface 41-9, thereby releasing aerosol precursor
which has reached that activation surface 41-9 from the porous
polymer material (or hollow reservoir) of the first region 35-9,
through the second region 36-9. That vapor and/or a mixture of
vapor and aerosol, may then pass into the air adjacent the
activation surface 41-9 and the heater or heaters 24-9.
[0773] FIG. 83 also illustrates an opening 38-9, which opening 38-9
is in communication with the air-intake apertures 20-9. A further
opening 39-9 communicates with a duct 40-9 within the housing 32-9,
which duct 40-9 communicates with the second end 18-9.
[0774] There is thus a fluid-flow path for air (referred to as an
air-flow pathway) between openings 38-9 and 39-9, linking the
apertures 20-9 and the second end 18-9 of the aerosol carrier. When
the user sucks or inhales, air is drawn along the air-flow pathway,
along the activation surface 41-9. A plate 33-9 forms a lower
surface of the air-flow pathway, the plate 33-9 being spaced from
the activation surface 41-9. It can be seen that the air-flow
pathway is in direct contact with parts of the activation surface
41-9, as the heater or heaters 24-9 may partially block that path
from the activation surface to the fluid flow pathway. The fluid
flow pathway is on the opposite side of the heater or heaters 24-9
from the activation surface 41-9, so vapor must pass around the
heater or heaters 24-9 if it cannot pass therethrough.
[0775] One or more droplets of the aerosol precursor will be
released from the second plate 36b-9 and heated, to release vapor
or a mixture of aerosol and vapor into the air flowing in the
air-flow pathway between the openings 38-9, 39-9. The vapor or
mixture passes, as the user sucks and inhales, to the second end
18-9.
[0776] As mentioned above, the second region 36-9 of the
fluid-transfer article 34-9 comprises a first plate 36a-9 and a
second plate 36b-9. The first plate 36a-9 may be a molded polymer
disc so that is then easy to form the holes 37-9 therein by molding
the holes 37-9 when the plate 36a-9 is itself molded. The holes
37-9 are sufficiently large that they do not act as a capillary,
but instead define non-capillary spaces in the second region 36-9.
Hence, aerosol precursor is able to pass from the first region 35-9
of the fluid-transfer article to the second region 36-9 in a
non-capillary manner, into the holes 37-9, and then pass through
the second plate 36b-9 to the heater or heaters 24-9.
[0777] The second plate 36b-9 is made of a porous material which is
more heat-resistant than the material of the plate 36a-9, as it is
acted on directly by the heater or heaters 24-9. It may be fibrous,
made from e.g., ceramic fiber, glass fiber or carbon fiber.
Alternatively, it may be formed from a high-temperature porous
material such as porous glass or porous ceramic. Another
possibility is that the second plate 36b-9 may be of a porous
polymer material, such as the materials described previously with
reference to the layers 35a-9 and 35b-9 of the first region 35-9,
provided that the polymer material is sufficiently resistant to the
high temperatures to which it will be subject due to the heater or
heaters 24-9.
[0778] It is thought that the flow of air between openings 38-9 and
39-9 along the activation surface 41-9 and past the heater or
heaters 24-9 will have the effect of creating the lower air
pressure adjacent the activation surface 41-9 which will tend to
draw liquid through the porous second plate 36b-9 to the activation
surface 41-9. Thus, the transfer of aerosol precursor from the
fluid-transfer article 34-9 is facilitated.
[0779] As mentioned above, the fluid-transfer article 34-9, formed
by the first and second regions 35-9 and 36-9 and any further
reservoir of aerosol precursor, forms the consumable part of the
apparatus, in the sense that it can readily be replaced to enable
the aerosol precursor to be replaced once it is consumed. The
heater or heaters 24-9 are not part of the consumable elements.
Thus, the housing 32-9 containing the fluid-transfer article 34-9
may be separable from a housing 43-9 supporting the heater or
heaters 24-9 along the line B-B in FIG. 83 The plate 33-9 may be
integral with the further housing 43-9, and the openings 38-9 and
39-9 are formed in the further housing 43-9. The further housing
43-9 may be integral with the housing 26-9 containing the
electrical energy supply 28-9. It is for this reason that the
heater or heaters 24-9 make contact with, but are not bonded to,
the activation surface 41-9. The contact ensures the most efficient
heat transfer from the heater or heaters 24-9 to the second plate
36b-9 to heat the activation surface 41-9 but the heater or heaters
24-9 must be separable from that activation surface 41-9 to allow
removal of the housing 32-9 from the further housing 43-9 when the
fluid-transfer article 34-9 has become depleted. The line B to B
may therefore correspond to the plane of the activation surface
41-9.
[0780] In FIG. 83, the heater or heaters 24-9 may be separate or be
interconnected to form a single heater. For example, the heater may
be a coil, mesh or foil heater in which the parts of the heater
24-9 illustrated in FIG. 83 may be parts of a common structure.
Such a coil, mesh or foil heater is preferred so that any
restriction caused by the heater or heaters 24-9 on release of
aerosol or vapor from the activation surface is minimized, as vapor
and/or aerosol may pass through the heater or heaters 24-9.
However, it is also possible for the heater or heaters 24-9 to be a
solid unbroken strip or strips, provided that there is then enough
of the activation surface 41-9 not covered by the heater or heaters
24-9 to allow sufficient release of vapor and/or aerosol from the
activation surface 41-9.
[0781] In the illustrative examples of FIG. 83, the first layer
35a-9 of the first region 35-9 of the fluid-transfer article 34-9
is located at an "upstream" end of the fluid-transfer article 34-9
and the second plate 35b-9 of the second region 35b-9 is located at
a downstream" end of the fluid-transfer article 34-9. That is,
aerosol precursor is wicked, or is drawn, from the "upstream" end
of the fluid-transfer article 34-9 to the "downstream" end of the
fluid-transfer article 34-9 (as denoted by arrow A in FIG. 83).
[0782] In the arrangement of FIG. 83, the plate 33-9 has a planar
surface facing the activation surface 41-9. FIG. 84 illustrates an
arrangement in which the plate 33-9 has projections and recesses in
its upper surface, so that the recesses can form channels 31-9 for
air to flow therethrough. Other features which are the same as
those of FIG. 83 are indicated by the same reference numerals.
Thus, the channels 31-9 form the air-flow pathway along the
activation surface 41-9. In FIG. 84, the projections and recesses
form a square-wave or "castellated" structure. Further shapes are
possible, however, such as alternating peaks and troughs or
recesses with curved walls. All such arrangements permit channels
31-9 to be formed and allow air to flow along the activation
surface 41-9. This control of air flow improves the mixing of the
vaporized aerosol precursor into the air flow.
[0783] In the embodiment of FIG. 84, the peaks in the upper surface
of the plate 33-9 extend to the heater or heaters 24-9, with the
recesses between those peaks which form the channels 31-9 then
being aligned with the holes 37-9 formed in the second plate 35b-9
of the fluid-transfer article 34-9. Other alignments are possible,
and the projections need not reach all the way to the heater or
heaters 24-9. In general, however, the heater or heaters 24-9 may
restrict release of the vaporized aerosol precursor from parts of
the activation surface 41-9 on which those heater or heaters 24-9
are formed, so it will normally be desirable that the channels 31-9
are aligned with the part or parts of the activation surface 41-9
other than the part or parts on which the heater or heaters 24-9
are formed.
[0784] Note also that, in FIG. 84, the openings 38-9 and 39-9 are
not visible since they will be at the ends of the channels 31-9 to
allow air to pass from the opening 38-9 in to the channels 31-9,
and from those channels 31-9 out of the opening 39-9. Also, as in
FIG. 83, the housing 32-9 containing the fluid-transfer article
34-9 may be separable from the housing 43-9 containing the
intermediate structure 36-9 and the heater or heaters 24-9 along
the line B-B in FIG. 84.
[0785] In the arrangements shown in FIGS. 83 and 84, the apertures
38-9, 39-9 are on opposite sides of the housing 32-9. FIGS. 85 and
86 shows an alternative configuration, in which the fluid-transfer
article is annular, and both the first region 35-9 and the second
region 36-9 are then in the form of annuli. In FIGS. 86 and 87, the
structure of the fluid-transfer article 34-9, including the first
region 35-9 and the second region 36-9 may correspond generally to
that shown in FIG. 83 The internal structure of the first and
second regions 35-9 and 36-9 may be the same as in FIG. 83, but are
not illustrated in detail in FIGS. 85 and 86 for simplicity. The
heater or heaters 24-9 also cannot be seen in FIGS. 85 and 86, but
may be formed as in the arrangement of FIG. 83 or FIG. 84 However,
the air flow in the apparatus is discussed in more detail below.
Thus, FIGS. 85 and 86 illustrate an aerosol carrier 14-9 according
to one or more possible arrangements in more detail. FIG. 85 is a
cross-section side view illustration of the aerosol carrier 14-9
and FIG. 86 is a perspective cross-section side view illustration
of the aerosol carrier 14-9.
[0786] As can be seen from FIGS. 85 and 86, the aerosol carrier
14-9 is generally tubular in form. The aerosol carrier 14-9
comprises housing 32-9, which defines the external walls of the
aerosol carrier 14-9 and which defines therein a chamber in which
are disposed the fluid-transfer article 34-9 (adjacent the first
end 16-9 of the aerosol carrier 14-9) and internal walls defining
the fluid communication pathway 48-9. Fluid communication pathway
48-9 defines a fluid pathway for an outgoing air stream from the
channels 40-9 to the second end 18-9 of the aerosol carrier 14-9.
In the examples illustrated in FIGS. 85 and 86, the fluid-transfer
article 34-9 is an annular shaped element located around the fluid
communication pathway 48-9. The housing 32-9 containing the
fluid-transfer article 34-9 is separable from the housing 43-9
supporting heater or heaters 24-9.
[0787] In walls of the housing 43-9, there are provided inlet
apertures 50-9 to provide a fluid communication pathway for an
incoming air stream to reach the activation surface 41-9 of the
second region 36-9 of the fluid-transfer article 34-9.
[0788] In the illustrated example of FIGS. 85 and 86, the aerosol
carrier 14-9 further comprises a filter element 52-9. The filter
element 52-9 is located across the fluid communication pathway 48-9
such that an outgoing air stream passing through the fluid
communication pathway 48-9 passes through the filter element
52-9.
[0789] With reference to FIG. 86, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18-9 of the aerosol carrier
14-9, if configured as a mouthpiece), air is drawn into the carrier
through inlet apertures 50-9 extending through walls in the housing
32-9 of the aerosol carrier 14-9.
[0790] An incoming airstream 42a-9 from a first side of the aerosol
carrier 14-9 is directed to a first side of the second region 36-9
(e.g., via a gas communication pathway within the housing of the
carrier). An incoming air stream 42b-9 from a second side of the
aerosol carrier 14-9 is directed to a second side of the second
region 36-9 (e.g., via a gas communication pathway within the
housing of the carrier). When the incoming air stream 42a-9 from
the first side of the aerosol carrier 14-9 reaches the first side
of the second region 36-9, the incoming air stream 42a-9 from the
first side of the aerosol carrier 14-9 flows along the activation
surface 41-9 of the second region 36-9. Likewise, when the incoming
air stream 42b-9 from the second side of the aerosol carrier 14-9
reaches the second side of the second region 36-9, the incoming air
stream 42b-9 from the second side of the aerosol carrier 14-9 flows
along the activation surface 41-9 of the second region 36-9. The
air streams from each side are denoted by dashed lines 44a-9 and
44b-9 in FIG. 86 As these air streams 44a-9 and 44b-9 flow, aerosol
precursor on the activation surface 41-9 of the second region 36-9
is entrained in air streams 44a-9 and 44b-9.
[0791] In use, the heater or heaters 24-9 of the apparatus 12-9
raise a temperature of the second plate 36b-9 of the second region
36-9 to a sufficient temperature to release, or liberate, captive
substances (i.e., the aerosol precursor) to form a vapor and/or
aerosol, which is drawn downstream. As the air streams 44a-9 and
44b-9 continue their passages, more released aerosol precursor is
entrained within the air streams 44a-9 and 44b-9. When the air
streams 44a-9 and 44b-9 entrained with aerosol precursor meet at a
mouth of the outlet fluid communication pathway 48-9, they enter
the outlet fluid communication pathway 48-9 and continue until they
pass through filter element 52-9 and exit outlet fluid
communication pathway 48-9, either as a single outgoing air stream,
or as separate outgoing air streams 46-9 (as shown). The outgoing
air streams 46-9 are directed to an outlet, from where it can be
inhaled by the user directly (if the second end 18-9 of the aerosol
capsule 14-9 is configured as a mouthpiece), or via a mouthpiece.
The outgoing air streams 46-9 entrained with aerosol precursor are
directed to the outlet (e.g., via a gas communication pathway
within the housing of the carrier).
[0792] FIG. 87 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10-9.
[0793] As will be appreciated, in the arrangements described above,
the fluid-transfer article 34-9 is provided within a housing 32-9
of the aerosol carrier 14-9. In such arrangements, the housing of
the carrier 14-9 serves to protect the aerosol precursor-containing
fluid-transfer article 34-9, whilst also allowing the carrier 14-9
to be handled by a user without his/her fingers coming into contact
with the aerosol precursor liquid retained therein.
[0794] In any of the embodiments described above the second plate
36b-9 of the second region 36-9 may have a thickness of less than 5
mm. In other embodiments it may have a thickness of: less than 3.5
mm, less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9
mm, less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than
1.5 mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less
than 1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm,
less than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4
mm, less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.
[0795] Tenth Mode: A Dried Conductive Fluid is Used to Form at
Least One Heater Element on an Activation Surface of a
Fluid-Transfer Article
[0796] Aspects and embodiments of the tenth mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the tenth mode will be
apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0797] In general outline, one or more embodiments of the tenth
mode in accordance with the present disclosure may provide a system
for aerosol delivery in which an aerosol carrier may be inserted
into a receptacle (e.g., a "heating chamber") of an apparatus for
initiating and maintaining release of an aerosol from the aerosol
carrier.
[0798] Another end, or another end portion, of the aerosol carrier
may protrude from the apparatus and can be inserted into the mouth
of a user for the inhalation of aerosol released from the aerosol
carrier cartridge during operation of the apparatus.
[0799] Hereinafter, and for convenience only, "system for aerosol
delivery" shall be referred to as "aerosol delivery system".
[0800] Referring now to FIG. 88, there is illustrated a perspective
view of an aerosol delivery system 10-10 comprising an aerosol
generation apparatus 12-10 operative to initiate and maintain
release of aerosol from a fluid-transfer article in an aerosol
carrier 14-10. In the arrangement of FIG. 88, the aerosol carrier
14-10 is shown with a first end 16-10 thereof and a portion of the
length of the aerosol carrier 14-10 located within a receptacle of
the apparatus 12-10. A remaining portion of the aerosol carrier
14-10 extends out of the receptacle. This remaining portion of the
aerosol carrier 14-10, terminating at a second end 18-10 of the
aerosol carrier, is configured for insertion into a user's mouth. A
vapor and/or aerosol is produced when a heater (not shown in FIG.
88) of the apparatus 12-10 heats a fluid-transfer article in the
aerosol carrier 14-10 to release a vapor and/or an aerosol, and
this can be delivered to the user, when the user sucks or inhales,
via a fluid passage in communication with an outlet of the aerosol
carrier 14-10 from the fluid-transfer article to the second end
18-10.
[0801] The device 12-10 also comprises air-intake apertures 20-10
in the housing of the apparatus 12-10 to provide a passage for air
to be drawn into the interior of the apparatus 12-10 (when the user
sucks or inhales) for delivery to the first end 16-10 of the
aerosol carrier 14-10, so that the air can be drawn across an
activation surface of a fluid-transfer article located within a
housing of the aerosol carrier cartridge 14-10 during use.
Optionally, these apertures may be perforations in the housing of
the apparatus 12-10.
[0802] A fluid-transfer article (not shown in FIG. 88, but
described hereinafter with reference to FIGS. 92, 93, 94 95, 96,
97, 98 and 99) is located within a housing of the aerosol carrier
14-10. The fluid-transfer article contains an aerosol precursor
material, which may include at least one of: nicotine; a nicotine
precursor material; a nicotine compound; and one or more
flavorings. The fluid-transfer article is located within the
housing of the aerosol carrier 14-10 to allow air drawn into the
aerosol carrier 14-10 at, or proximal, the first end 16-10 to flow
across an activation surface of the fluid-transfer article. As air
passes across the activation surface of the fluid-transfer article,
an aerosol may be entrained in the air stream from a substrate
forming the fluid-transfer article, e.g., via diffusion from the
substrate to the air stream and/or via vaporization of the aerosol
precursor material and release from the fluid-transfer article
under heating.
[0803] The substrate forming the fluid-transfer article 34-10
comprises a porous material where pores of the porous material
hold, contain, carry, or bear the aerosol precursor material. In
particular, the porous material of the fluid-transfer article may
be a polymeric wicking material such as, for example, a sintered
material. Particular examples of material suitable for the
fluid-transfer article include: Polyetherimide (PEI);
Polytetrafluoroethylene (PTFE); Polyether ether ketone (PEEK);
Polyimide (PI); Polyethersulphone (PES); and Ultra-High Molecular
Weight Polyethylene. Other suitable materials may comprise, for
example, BioVyon.TM. (by Porvair Filtration Group Ltd) and
materials available from Porex.COPYRGT.. Further optionally, a
substrate forming the fluid-transfer article may comprise
Polypropylene (PP) or Polyethylene Terephthalate (PET). All such
materials may be described as heat resistant polymeric wicking
material in the context of the present disclosure.
[0804] The aerosol carrier 14-10 is removable from the apparatus
12-10 so that it may be disposed of when expired. After removal of
a used aerosol carrier 14-10, a replacement aerosol carrier 14-10
can be inserted into the apparatus 12-10 to replace the used
aerosol carrier 14-10.
[0805] FIG. 89 is a cross-sectional side view illustration of a
part of apparatus 12-10 of the aerosol delivery system 10-10. The
apparatus 12-10 comprises a receptacle 22-10 in which is located a
portion of the aerosol carrier 14-10. In one or more optional
arrangements, the receptacle 22-10 may enclose the aerosol carrier
14-10. The apparatus 12-10 also comprise a heater which will be
described in more detail later.
[0806] Air flows into the apparatus 12-10 (in particular, into a
closed end of the receptacle 22-10) via air-intake apertures 20-10.
From the closed end of the receptacle 22-10, the air is drawn into
the aerosol carrier 14-10 (under the action of the user inhaling or
sucking on the second end 18-10) and expelled at the second end
18-10. As the air flows into the aerosol carrier 14-10, it passes
across the activation surface of the fluid-transfer article. Heat
from the heater causes vaporization of aerosol precursor material
at the activation surface of the fluid-transfer article and an
aerosol is created in the air flowing over the activation surface.
Thus, through the application of heat in the region of the
activation surface of the fluid-transfer article, an aerosol is
released, or liberated, from the fluid-transfer article, and is
drawn from the material of the aerosol carrier unit by the air
flowing across the activation surface and is transported in the air
flow to via outlet conduits (not shown in FIG. 89) in the housing
of the aerosol carrier 14-10 to the second end 18-10. The direction
of air flow is illustrated by arrows in FIG. 89.
[0807] To achieve release of the captive aerosol from the
fluid-transfer article, the fluid-transfer article of the aerosol
carrier 14-10 is heated by the heater. As a user sucks or inhales
on second end 18-10 of the aerosol carrier 14-10, the aerosol
released from the fluid-transfer article and entrained in the air
flowing across the activation surface of the fluid-transfer article
is drawn through the outlet conduits (not shown) in the housing of
the aerosol carrier 14-10 towards the second end 18-10 and onwards
into the user's mouth.
[0808] Turning now to FIG. 90, a cross-sectional side view of the
aerosol delivery system 10-10 is schematically illustrated showing
the features described above in relation to FIGS. 88 and 89 in more
detail.
[0809] As can be seen, apparatus 12-10 comprises a housing 26-10,
in which are located the receptacle 22-10 and heater. The housing
26-10 also contains control circuitry (not shown) operative by a
user, or upon detection of air and/or vapor being drawn into the
device 12-10 through air-intake apertures 20-10, i.e., when the
user sucks or inhales. Additionally, the housing 26-10 comprises an
electrical energy supply 28-10, for example a battery. Optionally,
the battery comprises a rechargeable lithium-ion battery. The
housing 26-10 also comprises a coupling 30-10 for electrically (and
optionally mechanically) coupling the electrical energy supply
28-10 to control circuitry (not shown) for powering and controlling
operation of the heater.
[0810] Responsive to activation of the control circuitry of
apparatus 12-10, the heater heats the fluid-transfer article (not
shown in FIG. 90) of aerosol carrier 14-10. This heating process
initiates (and, through continued operation, maintains) release of
vapor and/or an aerosol from the activation surface of the
fluid-transfer article. The vapor and/or aerosol formed as a result
of the heating process is entrained into a stream of air being
drawn across the activation surface of the fluid-transfer article
(as the user sucks or inhales). The stream of air with the
entrained vapor and/or aerosol passes through the aerosol carrier
14-10 via outlet conduits (not shown) and exits the aerosol carrier
14-10 at second end 18-10 for delivery to the user. This process is
briefly described above in relation to FIG. 89, where arrows
schematically denote the flow of the air stream into the device
12-10 and through the aerosol carrier 14-10, and the flow of the
air stream with the entrained vapor and/or aerosol through the
aerosol carrier cartridge 14-10.
[0811] FIGS. 91 to 93 schematically illustrate the aerosol carrier
14-10 in more detail (and, in FIGS. 92 and 93, features within the
receptacle in more detail). FIG. 91 illustrates an exterior of the
aerosol carrier 14-10, FIG. 92 illustrates internal components of
the aerosol carrier 14-10 in an optional arrangement, and FIG. 93
illustrates internal components of the aerosol carrier 14-10 in
another optional arrangement.
[0812] FIG. 91 illustrates the exterior of the aerosol carrier
14-10, which comprises housing 32-10 for housing said
fluid-transfer article (not shown) and at least one other internal
component. The particular housing 32-10 illustrated in FIG. 91
comprises a tubular member, which may be generally cylindrical in
form, and which is configured to be received within the receptacle
of the apparatus. First end 16-10 of the aerosol carrier 14-10 is
for location to oppose the heater of the apparatus, and second end
18-10 (and the region adjacent the second end 18-10) is configured
for insertion into a user's mouth.
[0813] FIG. 92 illustrates some internal components of the aerosol
carrier 14-10 and of the heater 24-10 of apparatus 12-10.
[0814] Further components not shown in FIGS. 92 and 93 (see FIGS.
98 and 99) comprise: an inlet conduit, via which air can be drawn
into the aerosol carrier 14-10; an outlet conduit, via which an air
stream entrained with aerosol can be drawn from the aerosol carrier
14-10; a filter element; and a reservoir for storing aerosol
precursor material and for providing the aerosol precursor material
to the fluid-transfer article 34-10.
[0815] In FIGS. 92 and 93, the aerosol carrier is shown as
comprising the fluid-transfer article 34-10 located within housing
32-10. The material forming the fluid transfer article 34-10
comprises a porous structure, where pore diameter size varies
between one end of the fluid-transfer article 34-10 and another end
of the fluid-transfer article. In the illustrative examples of
FIGS. 92 and 93, the pore diameter size gradually decreases from a
first end remote from heater 24-10 (the upper end as shown in the
figure) to a second end proximal heater 24-10 (the lower end as
shown in the figure). Although the figure illustrates the pore
diameter size changing in a step-wise manner from the first to the
second end (i.e., a first region with pores having a diameter of a
first size, a second region with pores having a diameter of a
second, smaller size, and a third region with pores having a
diameter of a third, yet smaller size), the change in pore size
from the first end to the second end may be gradual rather than
step-wise. This configuration of pores having a decreasing diameter
size from the first end and second end can provide a wicking
effect, which can serve to draw fluid from the first end to the
second end of the fluid-transfer article 34-10.
[0816] The fluid-transfer article 34-10 comprises a first region
34a-10 for holding an aerosol precursor. In one or more
arrangements, the first region 34a-10 of the fluid-transfer article
34-10 comprises a reservoir for holding the aerosol precursor. The
first region 34a-10 can be the sole reservoir of the aerosol
carrier 14-10, or it can be arranged in fluid communication with a
separate reservoir, where aerosol precursor is stored for supply to
the first region 34a-10.
[0817] The fluid-transfer article 34-10 also comprises a second
region 34b-10. Aerosol precursor is drawn from the first region
34a-10 to the second region 34b-10 by the wicking effect of the
substrate material forming the fluid transfer article. Thus, the
first region 34a-10 is configured to transfer the aerosol precursor
to the second region 34b-10 of the article 34-10.
[0818] At the second end of fluid-transfer article 34-10, the
surface of the second region 34b-10 defines an activation surface
38-10. The activation surface 38-10 is discontinuous such that at
least one channel 40-10 is formed in the activation surface 38-10.
In some arrangements, the discontinuities may be such that the
activation surface 38-10 is undulating.
[0819] In the illustrative examples of FIGS. 92 and 93, the
activation surface 38-10 comprises a plurality of grooves or
valleys therein to form an undulating surface, the grooves or
valleys being disposed in a parallel arrangement across the
activation surface 38-10. Thus, there are a plurality of channels
40-10 in the activation surface 38-10.
[0820] In the illustrative example of FIG. 92, the grooves or
valleys in the activation surface 38-10 provide alternating peaks
and troughs that give rise to a "saw-tooth" type profile. In one or
more optional arrangements, the activation surface may comprise a
"castellated" type profile (i.e., a "square wave" type profile),
for example, such as illustrated in the example of FIG. 93. In one
or more optional arrangements, the activation surface may comprise
a "sinusoidal" type profile. The profile may comprise a mixture of
two or more of the above profiles given as illustrative
examples.
[0821] In the illustrative examples of FIGS. 92 and 93, the first
region 34a-10 of the fluid-transfer article 34-10 is located at an
"upstream" end of the fluid-transfer article 34-10 and the second
region 34b-10 is located at a downstream" end of the fluid-transfer
article 34-10. That is, aerosol precursor is wicked, or is drawn,
from the "upstream" end of the fluid-transfer article 34-10 to the
"downstream" end of the fluid-transfer article 34-10 (as denoted by
arrow A in FIG. 92).
[0822] The aerosol precursor is configured to release an aerosol
and/or vapor upon heating. Thus, when the activation surface 38-10
receives heat conveyed from the heater, the aerosol precursor held
at the activation surface 38-10 is heated. The aerosol precursor,
which is captively held in material of the fluid-transfer article
at the activation surface 38-10 is released into an air stream
flowing through the channels 40-10.
[0823] The shape and/or configuration of the activation surface
38-10 and the associated shape(s) and/or configuration(s) of the
one or more channels 40-10 formed in the activation surface permit
air to flow across the activation surface 38-10 (through the one or
more channels 40-10) and also increase the surface area of the
activation surface 38-10 of the fluid-transfer article 34-10 that
is available for contact with a flow of air across the activation
surface 38-10.
[0824] As mentioned above, the apparatus has a heater. In the
illustrated examples of FIGS. 92 and 93, the heater is formed by
conductive fluid which is applied to parts of the activation
surface 38-10 and dried thereon, to form conductive heater elements
24-10. In FIG. 92, the conductive elements 24-10 are formed on the
peaks of the activation surface 38-10, and in FIG. 93 they are
formed on the lowermost part of the castellations. The heater
elements 24-10 are connected e.g., to the battery 28-10 via e.g.,
suitable electrical connections of the coupling 30-10.
[0825] In accordance with one preferred arrangement, the heater
elements 24-10 are formed by dipping the activation surface 38-10
into liquid conductive fluid, so that the conductive fluid adheres
or otherwise attaches to the appropriate parts of the activation
surface 38-10. The conductive material is then dried, so that the
conductive fluid becomes solid, thereby forming the heater elements
24-10. A material generally known as carbo e-therm may be used as
the conductive fluid, although other known conductive fluids may be
used instead. Dipping of the activation surface 38-10 in to the
conductive fluid thus becomes a simple way to produce the heater in
contact with the activation surface 38-10, the heater elements
24-10 forming the active part of that heater.
[0826] In the arrangement of FIG. 92, the heater elements 24-10 are
formed only on the peaks of the activation surface, with the rest
of the activation surface 38-10 being exposed in the channels
40-10. The heater elements 24-10 may limit or restrict the release
of the aerosol and/or vapor on heating, as they cover parts of the
activation surface, but the size of the heater elements 24-10 will
also affect the amount of heat that can be transferred to the
fluid-transfer article 34-10. Hence, it may be necessary to make
the heater elements larger, so that they extend at least partially
on the side walls of the channels 40-10 between the peaks and
troughs in FIG. 92 Similarly, in the arrangement of FIG. 93, the
heater elements 24-10 are shown on the flat surfaces of the
castellations, but they may again extend on the side walls thereof
if a greater heating area is needed.
[0827] In the illustrative examples of FIGS. 92 and 93, the heater
elements 24-10 are also in contact with a base plate 33-10 of the
casing 32-10, which base plate 33-10 is between the channels 40-10
and the coupling 30-10. It is possible, however, for there to be a
gap between the heater elements 24-10 and the base plate 33-10. In
such a case, air may pass from one channel 40-10 to another around
the heater elements 24-10.
[0828] FIGS. 94 and 95 show perspective view illustrations of the
fluid-transfer article 34-10 of aerosol carrier and heater elements
24-10 of the apparatus of the system for aerosol delivery. In
particular, these figures illustrate air flows across the
activation surface 38-10 when the apparatus is in use in a first
arrangement of the fluid-transfer article 34-10 (see FIG. 94), and
in a second arrangement of the fluid-transfer article 34-10 (see
FIG. 95).
[0829] In the illustrated example of use of the apparatus
schematically illustrated in FIG. 94, when a user sucks on a
mouthpiece of the apparatus, air is drawn into the carrier through
inlet apertures (not shown) provided in a housing of the carrier.
An incoming air stream 42-10 is directed to the activation surface
38-10 of the fluid-transfer article 34-10 (e.g., via a fluid
communication pathway within the housing of the carrier). When the
incoming air stream 42-10 reaches a first side of the activation
surface 38-10, the incoming air stream 42-10 flows across the
activation surface 38-10 via the one or more channels 40-10. The
air stream flowing through the one or more channels 40-10 is
denoted by dashed line 44-10 in FIG. 94 As the air stream 44-10
flows through the one or more channels 40-10, aerosol precursor at
activation surface 38-10, across which the airstream 44-10 flows,
is released from the activation surface 38-10 by heat conveyed to
the activation surface from the heater elements 24-10. Aerosol
precursor released from the activation surface 38-10 in this manner
is then entrained in the air stream 44-10 flowing through the one
or more channels 40-10.
[0830] In use, the heater elements 24-10 of the apparatus 12-10
convey heat to the fluid transfer article 34-10 to raise the
temperature of the activation surface 38-10 to a sufficient
temperature to release, or liberate, captive substances (i.e., the
aerosol precursor) held at the activation surface 38-10 of the
fluid-transfer article 34-10 to form a vapor and/or aerosol, which
is drawn downstream across the activation surface 38-10 of the
fluid-transfer article. As the air stream 44-10 continues its
passage in the one or more channels 40-10, more released aerosol
precursor is entrained within the air stream 44-10. When the air
stream 44-10 entrained with aerosol precursor exits the one or more
channels 40-10 at a second side of the activation surface 38-10, it
is directed to an outlet, from where it can be inhaled by the user
via a mouthpiece. An outgoing air stream 46-10 entrained with
aerosol precursor is directed to the outlet (e.g., via a fluid
communication pathway within the housing of the carrier).
[0831] Therefore, operation of the apparatus will cause heat from
the heater elements 24-10 to be transferred to the activation
surface 38-10 of the fluid-transfer article. At a sufficiently high
temperature, captive substances held at the activation surface
38-10 of the fluid-transfer article 34-10 are released, or
liberated, to form a vapor and/or aerosol. Thus, when a user draws
on a mouthpiece of the apparatus, the released substances from the
fluid-transfer article are drawn away from the activation surface
38-10 (entrained in a stream of air) and condense to form an
aerosol that is drawn through a gas communication pathway for
delivery to an outlet, which is in fluid communication with the
mouthpiece.
[0832] As the aerosol precursor is released from the activation
surface 38-10, a wicking effect of the fluid-transfer article 34-10
causes aerosol precursor within the body of the fluid-transfer
article to migrate to the activation surface 38-10 to replace the
aerosol precursor released from the activation surface 38-10 into
air stream 44-10.
[0833] Operation of the heater elements 24-10 is controlled by
control circuitry (not shown), which is operable to actuate the
heater elements 24-10 responsive to an actuation signal from a
switch operable by a user or configured to detect when the user
draws air through a mouthpiece of the apparatus by sucking or
inhaling. In an optional arrangement, the control circuitry
operates to actuate the heater elements 24-10 with as little delay
as possible from receipt of the actuation signal from the switch,
or detection of the user drawing air through the mouthpiece. This
may affect near instantaneous heating of the activation surface
38-10 of the fluid-transfer article 34-10.
[0834] In the illustrated example of use of the apparatus
schematically illustrated in FIG. 95, rather than the case of FIG.
94 where air is drawn toward the activation surface 38-10 from one
side only (and exits from the one or more channels 40-10 at an
opposite side), a gas communication pathway for an incoming air
stream is configured to deliver the incoming air stream to the
activation surface 38-10 from both sides of the fluid-transfer
article, and thus from both ends of the channels 40-10 formed
therein. In such an arrangement, a gas communication pathway for an
outlet airstream may be provided through the body of the
fluid-transfer article 34-10. An outlet fluid communication pathway
for an outlet airstream in the illustrative example of FIG. 95 is
denoted by reference number 48-10.
[0835] Thus, in the illustrative example of FIG. 95, when a user
draws on a mouthpiece of the apparatus, air is drawn into the
carrier 14-10 through inlet apertures (not shown) provided in a
housing of the carrier. An incoming air stream 42-10a from a first
side is directed to a first side of the activation surface 38-10 of
the fluid-transfer article 34-10 (e.g., via a gas communication
pathway within the housing of the carrier 14-10). An incoming air
stream 42-10b from a second side is directed to a second side of
the activation surface 38-10 of the fluid-transfer article 34-10
(e.g., via a gas communication pathway within the housing of the
carrier 14-10). When the incoming air stream 42-10a from the first
side reaches the first side of the activation surface 38-10, the
incoming air stream 42-10a flows across the activation surface
38-10 via the one or more channels 40-10. Likewise, when the
incoming air stream 42-10b from the second side reaches the second
side of the activation surface 38-10, the incoming air stream
42-10b flows across the activation surface 38-10 via the one or
more channels 40-10. The air streams 42a-10, 42b-10 from each side
flowing through the one or more channels 40-10 are denoted by
dashed lines 44a-10 and 44b-10 in FIG. 95 As air streams 44a-10 and
44b-10 flow through the one or more channels 40-10, aerosol
precursor in the activation surface 38-10, across which the air
streams 44a-10 and 44b-10 flow, is released from the activation
surface 38-10 by heat conveyed to the activation surface from the
heater elements 24-10. Aerosol precursor released from the
activation surface 38-10 is entrained in air streams 44a-10 and
44b-10 flowing through the one or more channels 40-10.
[0836] In use, the heater elements 24-10 of the apparatus 12-10
convey heat to the fluid-transfer article 34-10 to raise a
temperature of the activation surface 38-10 to a sufficient
temperature to release, or liberate, captive substances (i.e., the
aerosol precursor) held at the activation surface 38-10 of the
fluid-transfer article 34-10 to form a vapor and/or aerosol, which
is drawn downstream across the activation surface 38-10 of the
fluid-transfer article. As the air streams 44a-10 and 44b-10
continue their passages in the one or more channels 40-10, more
released aerosol precursor is entrained within the air streams
44a-10 and 44b-10. When the air streams 44a-10 and 44b-10 entrained
with aerosol precursor meet at a mouth of the outlet fluid
communication pathway 48-10, they enter the outlet fluid
communication pathway 48-10 and continue until they exit outlet
fluid communication pathway 48-10, either as a single outgoing air
stream 46-10 (as shown), or as separate outgoing air streams. The
outgoing air stream 46-10 is directed to an outlet, from where it
can be inhaled by the user via a mouthpiece. The outgoing air
stream 46-10 entrained with aerosol precursor is directed to the
outlet (e.g., via a gas communication pathway within the housing of
the carrier 14-10).
[0837] FIGS. 96 and 97 are perspective end view illustrations of a
fluid-transfer article 34-10 of the aerosol carrier according to
one or more arrangements. These figures show different types of
channel configurations as illustrative examples. In both
illustrative examples of a channel configuration, as shown in FIGS.
96 and 97, the fluid-transfer article 34-10 comprises a cylindrical
member, which comprises a central bore extending therethrough for
fluid communication between the activation surface 38-10 and an
outlet, from where an outgoing air stream can be delivered for
inhalation. The central bore serves as a fluid communication
pathway 48-10 (e.g., as described above in relation to FIG. 96).
Note that, in the arrangements of FIGS. 96 and 97, the channels
40-10 extend radially and the sectional views of FIGS. 96 and 97
are along the length of two channels at opposite radial positions
relative to the central bore of the fluid-transfer article. The
heating elements 24-10 are therefore not visible in FIGS. 96 and
97, although they will be present in similar positions, relative to
the channels 40-10, as the heating elements 24-10 and channels
40-10 in FIGS. 92 to 95.
[0838] In both illustrative examples of FIGS. 96 and 97, an
incoming air stream 42-10 is directed to a mouth of a channel 40-10
formed between the activation surface 38-10 of the fluid-transfer
article 34-10 and conduction element (not shown), or between the
activation surface 38-10 and a heater (not shown). In both
illustrative examples of FIGS. 96 and 97, the mouth of the channel
40-10 is located at an outer edge of the fluid-transfer article
34-10 and an exit from the channel 40-10 (in fluid communication
with the fluid communication pathway 48-10) is located toward a
center of the fluid-transfer article. Therefore, the incoming air
stream 42-10 enters the channel 40-10 via channel mouth at the
outer edge of the fluid-transfer article 34-10 and moves toward the
center of the fluid-transfer article 34-10 as directed by the
channel 40-10. As described above, as the air stream passes across
activation surface 38-10 through channel 40-10, aerosol precursor
is released from the activation surface 38-10 and is entrained in
air stream 44-10. Air stream 44-10 continues to flow through the
channel 40-10 until it reaches an exit thereof, from where it
enters the fluid communication pathway 48-10 and proceeds as an
outgoing air stream 46-10 entrained with aerosol precursor toward
the outlet.
[0839] In both illustrative examples of FIGS. 96 and 97, the heater
elements 24-10 are not shown, but they will be formed on the raised
parts 45-10 of the activation surface, and optionally on part of
the sides of the channels 40-10.
[0840] In both illustrative examples of FIGS. 96 and 97, the
valleys or grooves of the activation surface 38-10 that form part
of the channel 40-10 are arranged to define a circuitous route
20-10 across the activation surface. In the illustrative examples,
the route is a spiral path, but in optional arrangements, may be
meandering or circuitous in some other manner. In optional
arrangements, the activation surface may be located to face
outwardly from the cylinder, such that the groove(s) or valley(s)
may be in the outer surface of the cylinder forming the
fluid-transfer article. These grooves or valleys may be arranged in
parallel in a direction along the length of the cylinder. The
groove(s) or valley(s) may be arranged in a spiral manner around
the outside of the cylinder. In optional arrangements, the
activation surface 38-10 may be located to face inwardly from the
cylinder (i.e., surrounding the central bore), such that the
groove(s) or valley(s) may be in the inner surface of the cylinder
forming the fluid-transfer article 34-10. These grooves or valleys
may be arranged in parallel in a direction along the length of the
cylinder. The groove(s) or valley(s) may be arranged in a spiral
manner around the inside of the cylinder.
[0841] FIGS. 98 and 99 illustrate an aerosol carrier 14-10
according to one or more possible arrangements in more detail. FIG.
98 is a cross-section side view illustration of the aerosol carrier
14-10 and FIG. 99 is a perspective cross-section side view
illustration of the aerosol carrier 14-10 of FIG. 98.
[0842] As can be seen from FIGS. 98 and 99, the aerosol carrier
14-10 is generally tubular in form. The aerosol carrier 14-10
comprises housing 32-10, which defines the external walls of the
aerosol carrier 14-10 and which defines therein a chamber in which
are disposed the fluid-transfer article 34-10 (adjacent the first
end 16-10 of the aerosol carrier 14-10) and internal walls defining
the fluid communication pathway 48-10. Fluid communication pathway
48-10 defines a fluid pathway for an outgoing air stream from the
channels 40-10 to the second end 18-10 of the aerosol carrier
14-10. In the examples illustrated in FIGS. 98 and 99, the
fluid-transfer article 34-10 is an annular shaped element located
around the fluid communication pathway 48-10, and the channels
40-10 formed so as to extend radially across its activation
surface.
[0843] In walls of the housing 32-10, there are provided inlet
apertures 50-10 to provide a fluid communication pathway for an
incoming air stream to reach the fluid-transfer article 34-10, and
particularly the one or more channels 40-10 in the activation
surface of the fluid-transfer article 34-10. Note that, although
the heater elements 24-10 are not shown in FIGS. 98 and 99, will be
present on the activation surface 38-10 parts other than at the
channels 40-10.
[0844] In the illustrated example of FIGS. 98 and 99, the aerosol
carrier 14-10 further comprises a filter element 52-10. The filter
element 52-10 is located across the fluid communication pathway
48-10 such that an outgoing air stream passing through the fluid
communication pathway 48-10 passes through the filter element
52-10.
[0845] With reference to FIG. 99, when a user sucks on a mouthpiece
of the apparatus (or on the second end 18-10 of the aerosol carrier
14-10, if configured as a mouthpiece), air is drawn into the
carrier through inlet apertures 50-10 extending through walls in
the housing 32-10 of the aerosol carrier 14-10. An incoming air
stream 42-10a from a first side of the aerosol carrier 14-10 is
directed to a first side of the activation surface 38-10 of the
fluid-transfer article 34-10 (e.g., via a gas communication pathway
within the housing of the carrier). An incoming air stream 42-10b
from a second side of the aerosol carrier 14-10 is directed to a
second side of the activation surface 38-10 of the fluid-transfer
article 34-10 (e.g., via a gas communication pathway within the
housing of the carrier). When the incoming air stream 42-10a from
the first side of the aerosol carrier 14-10 reaches the first side
of the activation surface 38-10, the incoming air stream 42-10a
from the first side of the aerosol carrier 14-10 flows across the
activation surface 38-10 via the one or more channels 40-10 in the
activation surface 38-10. Likewise, when the incoming air stream
42-10b from the second side of the aerosol carrier 14-10 reaches
the second side of the activation surface 38-10, the incoming air
stream 42-10b from the second side of the aerosol carrier 14-10
flows across the activation surface 38-10 via the one or more
channels 40-10 in the activation surface 38-10. The air streams
from each side flowing through the one or more channels 40-10 are
denoted by dashed lines 44a-10 and 44b-10 in FIG. 99 As air streams
44a-10 and 44b-10 flow through the one or more channels 40-10,
aerosol precursor in the activation surface 38-10, across which the
air streams 44a-10 and 44b-10 flow, is released from the activation
surface 38-10 by heat conveyed to the activation surface from the
heater elements 24-10. Aerosol precursor released from the
activation surface 38-10 is entrained in air streams 44a-10 and
44b-10 flowing through the one or more channels 40-10.
[0846] In use, the heater elements 24-10 of the apparatus 12-10
convey heat to the activation surface 38-10 of the fluid-transfer
article 34-10 to raise a temperature of the activation surface
38-10 to a sufficient temperature to release, or liberate, captive
substances (i.e., the aerosol precursor) held at the activation
surface 38-10 of the fluid-transfer article 34-10 to form a vapor
and/or aerosol, which is drawn downstream across the activation
surface 38-10 of the fluid-transfer article 34-10. As the air
streams 44a-10 and 44b-10 continue their passages in the one or
more channels 40-10, more released aerosol precursor is entrained
within the air streams 44a-10 and 44b-10. When the air streams
44a-10 and 44b-10 entrained with aerosol precursor meet at a mouth
of the outlet fluid communication pathway 48-10, they enter the
outlet fluid communication pathway 48-10 and continue until they
pass through filter element 52-10 and exit outlet fluid
communication pathway 48-10, either as a single outgoing air
stream, or as separate outgoing air streams 46-10 (as shown). The
outgoing air streams 46-10 are directed to an outlet, from where it
can be inhaled by the user directly (if the second end 18-10 of the
aerosol capsule 14-10 is configured as a mouthpiece), or via a
mouthpiece. The outgoing air streams 46-10 entrained with aerosol
precursor are directed to the outlet (e.g., via a gas communication
pathway within the housing of the carrier).
[0847] When the user initially draws on a mouthpiece of the
apparatus (or one the second end 18-10 of the aerosol carrier
14-10, if configured as a mouthpiece), this will cause an air
column located in the fluid communication pathway 48-10 to move
towards the outlet. In turn, this will draw air into the fluid
communication pathway from the one or more channels 40-10. This
will cause a pressure drop in the channels 40-10. To equalize the
pressure in the channels 40-10, air will be drawn into the aerosol
carrier 14-10, and thus into the channels 40-10 via the inlet
apertures 50-10. During the period of lower pressure in the one or
more channels 40-10 when the user begins to draw, aerosol precursor
in the fluid-transfer medium will be released into the channels
from the activation surface 38-10, because the aerosol precursor is
drawn into the one or more channels by way of the lower pressure.
This effect is in addition to the effect of releasing the aerosol
precursor from the activation surface 38-10 by way of heat conveyed
from the heater. The drawing of the aerosol precursor from the
activation surface 38-10 by way of the user sucking on the
mouthpiece of the apparatus (or one the second end 18-10 of the
aerosol carrier 14-10, if configured as a mouthpiece) may produce a
dragging effect on the volumetric rate of flow experienced by the
user during a suction action, i.e., the user may have to suck
harder to achieve a same volumetric rate of flow. This effect may
manifest itself as a similar physical sensation experienced by the
user as those experienced from a traditional smoking or tobacco
product.
[0848] FIG. 100 is an exploded perspective view illustration of a
kit-of-parts for assembling an aerosol delivery system 10-10.
[0849] As will be appreciated, in the arrangements described above,
the fluid-transfer article 34-10 is provided within a housing 32-10
of the aerosol carrier 14-10. In such arrangements, the housing of
the carrier 14-10 serves to protect the aerosol
precursor-containing fluid-transfer article 34-10, whilst also
allowing the carrier 14-10 to be handled by a user without his/her
fingers coming into contact with the aerosol precursor liquid
retained therein. In such arrangements, it will be appreciated that
the carrier 14-10 has a multi-part construction. In some cases,
this might be considered somewhat disadvantageous because it
requires a relatively complicated assembly procedure which can be
both time-consuming and expensive.
[0850] Turning now to consider FIG. 101, there is illustrated
another possible aspect of the tenth mode of the fluid-transfer
article 34-10, which may be employed in some arrangements, and
which may permit the creation of a significantly simplified carrier
14-10.
[0851] FIG. 101 illustrates an alternative fluid-transfer article
34-10 with airflow channels 40-10 in the activation surface 38-10.
In the arrangement of FIG. 101, the substrate forming the
fluid-transfer article 34-10 again comprises a porous material
where pores of the porous material hold, contain, carry, or bear
the aerosol precursor material. It is envisaged, for example, that
the same types of substrate material may be used in the arrangement
illustrated in FIG. 101 as in the previously-described
arrangements. In particular, therefore, the porous material of the
fluid-transfer article 34-10 may be a polymeric wicking material.
However, in the arrangement illustrated in FIG. 101, the substrate
material includes an integrally formed peripheral wall 54-10.
[0852] It is proposed that the peripheral wall 54-10 may be formed
by treating the outermost surface of the porous substrate material
of the fluid-transfer article 34-10 so as to render the surface
substantially liquid-impermeable. For example, it is envisaged that
in some arrangements the substrate material may be locally heated
so as to fuse the material and close up its internal pores in the
localized region of the surface. Alternatively, it is envisaged
that the substrate material may be treated by a sintering process
in order to create the liquid-impermeable peripheral wall 54-10.
The peripheral wall 54-10 may alternatively be created by a
chemical treatment process to render the substrate material
substantially liquid-impermeable in the region of its outermost
surface. As will therefore be appreciated, the peripheral wall
54-10 may be considered to take the form of a skin formed from the
material of the substrate itself.
[0853] The peripheral wall may be created in this manner so as to
substantially completely circumscribe the substrate material. It is
to be appreciated, however, that the activation surface 38-10 of
the fluid-transfer article 34-10 will not be treated in this
manner, thereby ensuring that it will retain the function described
above in detail in cooperation with the heater elements 24-10. The
thickness of the peripheral wall 54-10 formed from the substrate
may vary depending on the desired physical properties of the
fluid-transfer article 34-10. For example, a relatively thin wall
54-10 might be desirable in some circumstances, as this may retain
some flexibility in the material, thereby providing a
fluid-transfer article which will feel soft in the hands of a user.
Alternatively, a relatively thick peripheral wall 54-10 might be
desirable in arrangements where the wall 54-10 is required to
provide some structural rigidity to the fluid-transfer article
34-10. The wall 54-10 may therefore have a thickness of less than 3
mm; or less than 2.5 mm; or less than 2 mm; or less than 1.5 mm; or
less than 1 mm; or less than 0.9 mm; or less than 0.8 mm; or less
than 0.7 mm; or less than 0.6 mm; or less than 0.5 mm; or less than
0.4 mm; or less than 0.3 mm; or less than 0.2 mm; or less than 0.1
mm in some embodiments.
[0854] As will be appreciated, the liquid-impermeable nature of the
resulting peripheral wall or skin means that the fluid-transfer
article 34-10 may be handled by a user without getting his or her
fingers wet from the aerosol precursor liquid retained therein.
This opens up the possibility of the fluid-transfer article 34-10
being used without an enclosing housing 32-10, as was necessary in
the previously-described arrangements. It is therefore envisaged
that in some arrangements, the fluid-transfer article 34-10 may
itself define an entire aerosol carrier 14-10. Furthermore, it is
envisaged that in some embodiments, a fluid-transfer article 34-10
in accordance with this proposal may be provided in the form of a
unitary monolithic element of substrate material and could,
therefore, take the form of a single-piece consumable or carrier
14-10 for an aerosol-delivery system 10-10, which may be provided
pre-filled with aerosol precursor liquid and which may be discarded
when the initial volume of precursor has been used. A single-piece
consumable of this type offers very significant advantages in terms
of cost of manufacture, and from an environmental point of
view.
[0855] Turning now to consider FIG. 102, there is illustrated a
fluid-transfer article 34-10 in combination with heater elements
24-10. The fluid-transfer article 34-10 may have a peripheral wall
or skin formed in the manner described above, although this is not
essential and indeed is not present in the particular arrangement
illustrated in FIG. 102. The particular feature of the
fluid-transfer article 34-10 illustrated in FIG. 102 which is of
relevance is the cross-sectional profile of the channels 40-10
defined in the activation surface 38-10 of the second region 34b-10
of the article. As will be noted, the channels 40-10 visible in
FIG. 102 have a significantly different profile to the "saw-tooth"
type profile illustrated in FIG. 92, and to the "castellated" type
profile illustrated in FIG. 93 Nevertheless, as will be explained,
the channel profile illustrated in FIG. 102 shares a characteristic
with the "saw-tooth" type profile illustrated in FIG. 92.
[0856] The activation surface 38-10 of the arrangement of FIG. 102
is discontinuous in a manner such that it includes a plurality of
spaced-apart angled surface portions 57-10. The angled surface
portions 57-10 of the activation surface 38-10 are arranged in
pairs, the members of each pair cooperating to define opposing
angled walls of a respective channel 40-10. In the particular
channel configuration illustrated in FIG. 102, each channel 40-10
also comprises a respective ceiling portion 59-10 between the two
spaced-apart angled surfaces 57-10. Each channel 40-10 further
comprises a pair of opposed side walls 60-10, each of which
interconnects an edge of a respective angled surface portion 57-10
and a respective side edge of the ceiling portion 59-10.
[0857] In the arrangement of FIG. 102, the heater elements 24-10
cover not only the peaks of the activation surface 38-10, but also
the angled surface portions 57-10 in the side walls 60-10. This
maximizes the heat that can be transferred to the fluid-transfer
article 34-10, but it also has the effect of limiting the parts of
the activation surface from which aerosol precursor can pass to the
ceiling portions 59-10. If this is found to be insufficient, the
side walls 57-10 may be left uncovered by the heater elements
24-10.
[0858] In the arrangement illustrated in FIG. 102, the ceiling
portion 59-10 of each channel 40-10 presents a substantially planar
surface in spaced-relation to the heating surface 55-10. However,
as will be explained below in relation to FIG. 93, in other
arrangements the ceiling portion may alternatively present an
arcuate surface towards the heating surface 55-10.
[0859] As will be observed, the "saw-tooth" channel profile
illustrated in FIG. 92 can be considered somewhat similar to the
profile illustrated in FIG. 102, in the sense that it is also
defined by an activation surface 38-10 which is discontinuous in a
manner effective to include angled surface portions arranged to
form acute intersection angles with a planar heating surface.
[0860] It is believed that the aforementioned angled surfaces
57-10, and more particularly their acute intersection angles 58-10
to the heater surface 55-10 aid in the release of liquid aerosol
precursor from the substrate material of the fluid-transfer article
34-10. It is believed that the sharp corners defined at the angled
points of intersection between the angled surfaces 57-10 and the
heater surface 55-10 create improved vaporization sites for the
release of aerosol precursor, and allow the liquid to form menisci
along the corner edges of the channels 40-10, at the sites of the
acute angles 58-10, on the heating surface 55-10. This has been
found to promote more efficient and quicker heating and
vaporization of the precursor liquid at the heating surface
55-10.
[0861] Turning now to consider FIG. 103, there is illustrated a
fluid-transfer article 34-10 having another configuration of
activation surface 38-10. The fluid-transfer article 34-10 is
illustrated as viewed from below the activation surface 38-10, and
in the absence of heater elements 24-10 for the sake of
clarity.
[0862] As will be observed from FIG. 103, the activation surface
38-10 is again discontinuous in a manner such that it includes a
plurality of spaced-apart angled surface portions 57-10, each of
which will form an acute intersection angle with a plane 55-10
aligned with their peaks. In the particular arrangement
illustrated, the intersection angles are considerably smaller than
in the configuration illustrated in FIG. 102 and may, for example,
be less than 20 degrees, although this is not essential.
[0863] Furthermore, it will also be observed that the angled
surface portions 57-10 of the activation surface 38-10 are again
arranged in pairs, the members of each pair cooperating to define
opposing angled walls of a respective channel 40-10. In the
particular channel configuration illustrated in FIG. 103, each
channel 40-10 also comprises a respective pair of generally planar
side walls 60-10 which are oriented so as to be substantially
perpendicular to the plane 55-10 when the fluid-transfer article
34-10 and a heater 24-10 (or conduction element 36-10) are
interengaged. The side walls 60-10 extend upwardly from the edges
of respective angled surface portions 57-10, and are interconnected
by a ceiling portion 59-10 of the respective channel 40-10. In this
arrangement, the ceiling portion 59-10 of each channel 40-10
defines an arcuate surface portion, which it will be understood
forms part of the discontinuous activation surface 38-10 of the
fluid-transfer article. The arcuate surface portion of each channel
40-10 is arranged to oppose the heating surface 55-10, in
spaced-relation thereto, and is concave towards the plane
55-10.
[0864] In such an arrangement, the heater elements 24-10 may be
formed on the angled surface portions 57-10, and possibly also on
parts of the side walls 60-10.
[0865] In preferred arrangements of the type illustrated in FIG.
103, it is proposed that the arcuate ceiling portion 59-10 of each
channel will blend smoothly into the side walls 60-10 of the
channel, thereby eliminating sharp corner edges in the upper region
of the channel 40-10. Such sharp corners can be seen, by
comparison, in the arrangement of FIG. 102, and are denoted at 61.
It has been found that by eliminating such sharp corners from the
upper regions of the channels' cross-sectional profile, more
efficient release or liberation of the aerosol precursor liquid
from the porous substrate of the fluid-transfer article 34-10 may
be achieved. This is because it has been found that liquid held in
the wicking material has a tendency to collect at sharp corners of
the channel profiles. This can present a disadvantage at the top of
each channel 40-10. This is because if excessive precursor liquid
collects around the upper regions of the channel 40-10, it can be
drawn out of the porous wicking material and sufficiently away from
the heating surface 55-10 by the airflow through the channel
without having been heated and thus vaporized by contact with the
heating surface.
[0866] In some arrangements, the or each channel 40-10 may be
configured to have the above-described arrangement of spaced-apart
side walls 60-10 and interconnecting arcuate ceiling portion 59-10
without the provision of the above-described angled surface
portions 57-10, such that the lower edges of the side walls 60-10
will be configured for direct contact with the heating surface
55-10 of a heater 24-10 or conduction element 36-10.
[0867] The porous layer may have a thickness of less than 5 mm. In
other embodiments it may have a thickness of: less than 3.5 mm,
less than 3 mm, less than 2.5 mm, less than 2 mm, less than 1.9 mm,
less than 1.8 mm, less than 1.7 mm, less than 1.6 mm, less than 1.5
mm, less than 1.4 mm, less than 1.3 mm, less than 1.2 mm, less than
1.1 mm, less than 1 mm, less than 0.9 mm, less than 0.8 mm, less
than 0.7 mm, less than 0.6 mm, less than 0.5 mm, less than 0.4 mm,
less than 0.3 mm, less than 0.2 mm, or less than 0.1 mm.
[0868] There has been described in the foregoing one or more
proposals for an aerosol delivery system, and parts thereof, that
avoids or at least ameliorates problems of the prior art.
[0869] In one or more optional arrangements, a fluid-transfer
article 34-10 containing nicotine and/or nicotine compounds may be
substituted or supplemented with a fluid-transfer article
configured to provide a flavored vapor and/or aerosol upon heating
of the fluid-transfer article by the heater elements 24-10 of the
apparatus 12-10. A precursor material for forming the flavored
vapor and/or aerosol upon heating is held within pores, spaces,
channels and/or conduits within the fluid-transfer article. The
precursor material may be extracted from a tobacco plant starting
material using a supercritical fluid extraction process.
Optionally, the precursor material is nicotine-free and comprises
tobacco-flavors extracted from the tobacco plant starting material.
Further optionally, the extracted nicotine-free precursor material
(e.g., flavors only) could have nicotine added thereto prior to
loading of the precursor material into the substrate of the carrier
unit. Further optionally, flavors and physiologically active
material may be extracted from plants other than tobacco
plants.
[0870] Eleventh Mode: A Heater of an Aerosol Delivery Device is
Supported by a Resilient Sealing Body
[0871] Aspects and embodiments of the eleventh mode of the present
disclosure will now be discussed with reference to the accompanying
figures. Further aspects and embodiments of the eleventh mode will
be apparent to those skilled in the art. All documents mentioned in
this text are incorporated herein by reference.
[0872] Referring to FIGS. 104 and 105, there is shown a smoking
substitute system comprising a smoking substitute device 100. In
this example, the substitute smoking system comprises a cartomizer
101 and a flavor pod 102. The cartomizer 101 may engage with the
smoking substitute device 100 via a push-fit engagement, a
screw-thread engagement, or a bayonet fit, for example. A
cartomizer may also be referred to as a "pod". The smoking
substitute system may be an aerosol delivery device according to
the present disclosure.
[0873] The flavor pod 102 is configured to engage with the
cartomizer 101 and thus with the substitute smoking device 100. The
flavor pod 102 may engage with the cartomizer 101 via a push-fit
engagement, a screw-thread engagement, or a bayonet fit, for
example. FIG. 105 illustrates the cartomizer 101 engaged with the
substitute smoking device 100, and the flavor pod 102 engaged with
the cartomizer 101. As will be appreciated, in this example, the
cartomizer 101 and the flavor pod 102 are distinct elements. Each
of the cartomizer 101 and the flavor pod may be an aerosol delivery
device.
[0874] As will be appreciated from the following description, the
cartomizer 101 and the flavor pod 102 may alternatively be combined
into a single component that implements the functionality of the
cartomizer 101 and flavor pod 102. Such a single component may also
be an aerosol delivery device according to the present disclosure.
In other examples, the cartomizer may be absent, with only a flavor
pod 102 present or vice versa.
[0875] A "consumable" component may mean that the component is
intended to be used once until exhausted, and then disposed of as
waste or returned to a manufacturer for reprocessing.
[0876] Referring to FIGS. 106 and 107, there is shown a smoking
substitute system comprising a smoking substitute device 100 and a
consumable 103. The consumable 103 combines the functionality of
the cartomizer 101 and the flavor pod 102. In FIG. 106, the
consumable 103 and the smoking substitute device 100 are shown
separated from one another. In FIG. 107, the consumable 103 and the
smoking substitute device 100 are engaged with each other.
[0877] Referring to FIG. 108, there is shown a consumable 103
engaged with a smoking substitute device 100 via a push-fit
engagement. The consumable 103 may be considered to have two
portions--a cartomizer portion 104 and a flavor pod portion 105,
both of which are located within a single component (as in FIGS.
106 and 107).
[0878] The consumable 103 includes an upstream airflow inlet 106
and a downstream airflow outlet 107. In other examples a plurality
of inlets and/or outlets are included. Between and fluidly
connecting the inlet 106 and the outlet 107 there is an airflow
passage 108. The outlet 107 is located at the mouthpiece 109 of the
consumable 103, and is formed by a mouthpiece aperture.
[0879] As above, the consumable 103 includes a flavor pod portion
105. The flavor pod portion 105 is configured to generate a first
(flavor) aerosol for output from the outlet 107 of the mouthpiece
109 of the consumable 103. The flavor pod portion 105 of the
consumable 103 includes a member 115. The member 115 acts as a
passive aerosol generator (i.e., an aerosol generator which does
not use heat to form the aerosol, also referred to as a "first
aerosol generator" in this example), and is formed of a porous
material. The member 115 comprises a supporting portion 117, which
is located inside a housing, and an aerosol generator portion 118,
which is located in the airflow passage 108. In this example, the
aerosol generator portion 118 is a porous nib.
[0880] A first storage reservoir 116 (in this example a tank) for
storing a first aerosol precursor (i.e., a flavor liquid) is
fluidly connected to the member 115. The porous nature of the
member 115 means that flavor liquid from the first storage 116 is
drawn into the member 115. As the first aerosol precursor in the
member 115 is depleted in use, further flavor liquid is drawn from
the first storage reservoir 116 into the member 115 via a wicking
action.
[0881] As described above, the aerosol generator portion 118 is
located within the airflow passage 108 through the consumable 103.
The aerosol generator portion 118 therefore constricts or narrows
the airflow passage 108. The aerosol generator portion 118 occupies
some of the area of the airflow passage, resulting in constriction
of the airflow passage 108. The airflow passage 108 is narrowest
adjacent to the aerosol generator portion 118. Since the
constriction results in increased air velocity and corresponding
reduction in air pressure at the aerosol generator portion 118, the
constriction is a Venturi aperture 119.
[0882] The cartomizer portion 104 of the consumable 103 includes a
second storage reservoir 110 (in this example a tank) for storing a
second aerosol precursor (i.e., e-liquid, which may contain
nicotine). At one end of the second storage reservoir 110 is a wick
support element 120, which supports a wick 111. As will be
described in more detail later, aerosol precursor passes through
one or more bores (not shown in FIG. 108) in the wick support
element 120 to reach the wick 111. The surface of the wick furthest
from the reservoir then acts as an activation surface from which
aerosol precursor will be released in the form of a vapor, or a
mixture of vapor and aerosol.
[0883] A heater 112 is a configured to heat the wick 111. The
heater 112 may be in the form of one or more resistive heating
filaments that abut the wick 111. The wick 111, the heater 112 and
the e-liquid storage reservoir 110 together act as an active
aerosol generator (i.e., an aerosol generator which uses heat to
form the aerosol, referred to as a "second aerosol generator" in
this example). The second storage reservoir 110, the wick support
element, and the wick 111 form a fluid-transfer article, as they
transfer aerosol precursor to the activation surface to be heated
by the heater 112.
[0884] The heater 112 is supported in the smoking substitute device
100 by a heater support element 130. There may be one or more
passages (not shown in FIG. 108) through the heater support element
130 to allow air to reach the activation surface of the wick 111
from an inlet (again not shown in FIG. 108) of the smoking
substitute device.
[0885] The smoking substitute device 100 includes an electrical
power source (not shown), for example a battery. That battery is
then connected via suitable electrical connections to the heater
112. The heater 112, the battery, and other components of the
smoking substitute system device 100 form a non-consumable part of
the device from which the consumable 103 may be connected and
disconnected.
[0886] In the arrangement of the smoking substitute device 100 of
FIG. 108, and in the arrangement to be described later, the
consumable 103 is separable from the rest of the smoking substitute
device 100. This allows the consumable 103 to be replaced, or
possibly refilled, when the first and/or second aerosol precursor
have been consumed by the user. Since the consumable 103 includes
the wick 111 and the wick support element 120, these components
will be removed when the consumable 103 is separated from the rest
of the smoking substitute device 100. The heater 112, on the other
hand, will remain when the consumable 103 is removed, so that it is
non-consumable.
[0887] In use, a user draws (or "sucks", or "pulls") on the
mouthpiece 109 of the consumable 103, which causes a drop in air
pressure at the outlet 107, thereby generating air flow through the
inlet, through the passages in the heater support element 130, past
the activation surface of the wick 111, along the airflow passage
108, out of the outlet 107 and into the user's mouth.
[0888] When the heater 112 is activated (by passing an electric
current through one or more heating filaments in response to the
user drawing on the mouthpiece 109) the e-liquid (aerosol
precursor) located in the wick 111 at the activation surface
adjacent to the or each heating filament is heated and vaporized to
form a vapor. The vapor condenses to form the second aerosol within
the airflow passage 108. Accordingly, the second aerosol is
entrained in an airflow along the airflow flow passage 108 to the
outlet 107 and ultimately out from the mouthpiece 109 for
inhalation by the user when the user 10 draws on the mouthpiece
109.
[0889] The substitute smoking device 100 supplies electrical
current to the heating filament or filaments of the heater 112 and
the heating filament or filaments heat up. As described, the
heating of the heating filament or filaments causes vaporization of
the e-liquid in the wick 111 to form the second aerosol.
[0890] As the air flows up through the airflow passage 108, it
encounters the aerosol generator portion 118. The constriction of
the airflow passage 108 caused by the aerosol generator portion 118
results in an increase in air velocity and corresponding decrease
in air pressure in the airflow in the vicinity of the porous
surface 118 of the aerosol generator portion 115. The corresponding
low-pressure region causes the generation of the first (flavor)
aerosol from the porous surface 118 of the aerosol generator
portion 118. The first (flavor) aerosol is entrained into the
airflow and ultimately is output from the outlet 107 of the
consumable 103 and thus from the mouthpiece 109 into the user's
mouth.
[0891] The first aerosol may be sized to inhibit pulmonary
penetration. The first aerosol may be formed of particles with a
mass median aerodynamic diameter that is greater than or equal to
15 microns, in particular, greater than 30 microns, more
particularly greater than 50 microns, yet more particularly greater
than 60 microns, and even more particularly greater than 70
microns.
[0892] The first aerosol may be sized for transmission within at
least one of a mammalian oral cavity and a mammalian nasal cavity.
The first aerosol may be formed by particles having a maximum mass
median aerodynamic diameter that is less than 300 microns, in
particular less than 200 microns, yet more particularly less than
100 microns. Such a range of mass median aerodynamic diameter will
produce aerosols which are sufficiently small to be entrained in an
airflow caused by a user drawing air through the flavor element and
to enter and extend through the oral and or nasal cavity to
activate the taste and/or olfactory receptors.
[0893] The second aerosol generated may be sized for pulmonary
penetration (i.e., to deliver an active ingredient such as nicotine
to the user's lungs). The second aerosol may be formed of particles
having a mass median aerodynamic diameter of less than or equal to
10 microns, preferably less than 8 microns, more preferably less
than 5 microns, yet more preferably less than 1 micron. Such sized
aerosols tend to penetrate into a human user's pulmonary system,
with smaller aerosols generally penetrating the lungs more easily.
The second aerosol may also be referred to as a vapor.
[0894] The size of aerosol formed without heating is typically
smaller than that formed by condensation of a vapor.
[0895] As a brief aside, it will be appreciated that the mass
median aerodynamic diameter is a statistical measurement of the
size of the particles/droplets in an aerosol. That is, the mass
median aerodynamic diameter quantifies the size of the droplets
that together form the aerosol. The mass median aerodynamic
diameter may be defined as the diameter at which 50% of the
particles/droplets by mass in the aerosol are larger than the mass
median aerodynamic diameter and 50% of the particles/droplets by
mass in the aerosol are smaller than the mass median aerodynamic
diameter. The "size of the aerosol", as may be used herein, refers
to the size of the particles/droplets that are comprised in the
particular aerosol.
[0896] Referring to FIG. 109, there is shown a flavor pod portion
202 of a consumable, the consumable providing an aerosol delivery
device in accordance with the disclosure. The consumable further
comprises a cartomizer portion (not shown in FIG. 109) having all
of the features of the cartomizer portion 104 described above with
respect to FIG. 108.
[0897] The flavor pod portion 202 comprises an upstream (i.e.,
upstream with respect to flow of air in use) inlet 204 and a
downstream (i.e., downstream with respect to flow of air in use)
outlet 206. Between and fluidly connecting the inlet 204 and the
outlet 206 the flavor pod portion 204 comprises an airflow passage
208. The airflow passage 208 comprises a first airflow branch 210
and a second airflow branch 212, each of the first airflow branch
210 and the second airflow branch 212 fluidly connecting the inlet
204 and the outlet 206. In other examples the airflow passage 208
may have an annular shape. The outlet 206 is located at the
mouthpiece 209 of the consumable 103, and is also referred to as a
mouthpiece aperture 206.
[0898] The flavor pod portion 202 comprises a storage 214, which
stores a first aerosol precursor. The storage 214 comprises a
reservoir 216 located within a chamber 218. The reservoir 216 is
formed of a first porous material.
[0899] The flavor pod portion 202 comprises a member 220, which
comprises an aerosol generator portion 222 and a supporting portion
223. The aerosol generator portion 222 is located at a downstream
end (an upper end in FIG. 109) of the member 220, while the
supporting portion 223 makes up the rest of the member 220. The
supporting portion 223 is elongate and substantially cylindrical.
The aerosol generator portion 222 is bulb-shaped, and comprises a
portion which is wider than the supporting portion 223. The aerosol
generator portion 222 tapers to a tip at a downstream end of the
aerosol generator portion 222.
[0900] The member 220 extends into and through the storage 214. The
member 220 is in contact with the reservoir 216. More specifically,
the supporting portion 223 extends into and through the storage 204
and is in contact with the reservoir 216. The member 220 is located
in a substantially central position within the reservoir 216 and is
substantially parallel to a central axis of the consumable. The
member 220 is formed of a second porous material.
[0901] The first and second airflow branches 210, 212 are located
on opposite sides of the member 220. Additionally, the first and
second airflow branches 210, 212 are located on opposite sides of
the reservoir 216. The first and second airflow branches 210, 212
branch in a radial outward direction (with respect to the central
axis of the consumable 200) downstream of the inlet 204 to reach
the opposite sides of the reservoir 216.
[0902] The aerosol generator portion 222 is located in the airflow
passage 208 downstream of the first and second airflow branches
210, 212. The first and second airflow branches 210, 212 turn in a
radially inward direction to merge at the member 220, at a point
upstream of the aerosol generator portion 222.
[0903] The aerosol generator portion 222 is located in a narrowing
section 224 of the airflow passage 208. The narrowing section 224
is downstream of the point at which the first and second airflow
branches 210 212 merge, but upstream of the mouthpiece aperture
207. The mouthpiece aperture 207 flares outwardly in the downstream
direction, such that a width of the mouthpiece aperture 207
increases in the downstream direction.
[0904] In use, when a user draws on the mouthpiece 209, air flow is
generated through the air flow passage 208. Air (comprising the
second aerosol from the cartomizer portion as explained above with
respect to FIG. 108) flows through the inlet 204 before the airflow
splits to flow through the first and second airflow branches 210,
212. Further downstream, the first and second airflow branches 210,
212 provide inward airflow towards the member 220 and the aerosol
generator portion 222.
[0905] As air flows past the aerosol generator portion in the
narrowing section 224, the velocity of the air increases, resulting
in a drop in air pressure. This means that the air picks up the
first aerosol precursor from the aerosol generator portion 222 to
form the first aerosol. The first aerosol has the particle size and
other properties described above with respect to FIG. 108.
[0906] As the first aerosol precursor is picked up by the air, the
member 220 transfers further first aerosol precursor from the
storage 214 to the aerosol generator portion 222. More
specifically, the member 220 wicks the first aerosol precursor from
the storage 214 to the aerosol generator portion 223.
[0907] In other examples, the storage 214 comprises a tank
containing the first aerosol precursor as free liquid, rather than
the reservoir 216 and the chamber 218. In such examples, the member
220 still extends into the tank to transfer first aerosol precursor
from the tank to the aerosol generator portion 223.
[0908] Further arrangements of the present disclosure will now be
described, which arrangements incorporate one or more features of
the aspects of the present disclosure. In the subsequent
arrangements, the smoking substitute device 100 includes a
consumable 103 in the form of a cartomizer, but does not include a
flavor pod. However, the smoking substitute device 100 of the
subsequent arrangements may be modified to incorporate a flavor pod
in a way similar to the arrangement of FIGS. 108 and 109.
[0909] As mentioned above, the wick 111 is supported by a wick
support element 120. FIG. 110 illustrates an arrangement of a
smoking substitute system in which these components are illustrated
in more detail, and in an exploded view. The wick support element
120 is mounted at an end of the second storage reservoir 111 and
has bores 122 therethrough to allow aerosol precursor in the second
storage reservoir 110 to pass to the wick 110. These bores may be
sized so that aerosol precursor may flow therethrough in a
non-capillary manner. Although, two bores 122 are visible in FIG.
110, there may be more arranged around the wick support element
120.
[0910] In the arrangement of FIG. 110, the wick support element 120
is made of a resilient material, such as rubber, and thus may
deform when force is applied thereto. In particular, when the
consumable 103 is mounted on the main body 100, the wick 111 is
brought into contact with the heater 112, and is held thereto by
the resilience of the wick support element 120. The wick support
element 120 may be sized so that it deforms slightly when the wick
111 is in contact with the heater 112, so as to provide a biasing
force to urge the wick 111 into firm contact with the heater
112.
[0911] The wick 111 has an opening 124 at its center, which is
aligned with a passageway 126 through the wick support element 122.
The passageway 126 communicates with the air-flow passage 108 shown
in FIG. 108 so that air, together with vapor or a mixture of vapor
and aerosol, will pass to the user. The surface of the wick 111
closest to the heater 112 acts as an activation surface for the
aerosol precursor and, as the wick 111 is heated by the heater 112,
aerosol precursor is released from the activation surface in the
form of vapor or a mixture of vapor and aerosol, it can then pass
through the opening 124 and the passageway 126 into the air-flow
passage 108.
[0912] As illustrated in FIG. 110, the heater 112 is mounted on a
heater support element 130, which may act as an end wall of a
battery housing and which may itself be supported by a support wall
132. The casing of the main body 100 (not shown in FIG. 110) will
enclose the support wall 132 and parts of the heater support
element 130. In order for air to flow from the activation surface
of the wick 111 through the opening 124 and into the passage 126,
air must first reach the activation surface of the wick 111. The
support wall 132 may thus have a bore 134 therethrough, which
communicates with passages 136 (not shown in FIG. 110) through the
heater support element 130. FIG. 111 illustrates these passages 136
and shows that they open immediately adjacent the heater 112 and
hence adjacent the activation surface of the wick 111. The casing
of the main body 100 may be provided with an inlet at a suitable
location, to allow air to reach the bore 134, and hence to flow to
the passages 136 in the heater support element 130. Hence, when the
user draws on the mouthpiece 109 of the consumable 103, air is
drawn into the casing of the main body 100 through the bore 134 and
the passages 136 to reach the activation surface of the wick 111
adjacent the heater 112. That air then passes, together with vapor
or mixture of aerosol and vapor generated by heating of the aerosol
precursor by the heater 112, through the opening 124 in the wick
111 to the passage 126, and hence to the air-flow passage 108, and
then to user, as has previously been described.
[0913] Note that in the arrangement of FIGS. 110 and 111, the
heater 112 will need to be connected to a power source, such as a
battery, and there may then need to be additional bores (not shown
in FIGS. 110 and 111) through the heater support element 130 and
the support wall 132 to allow electrical leads to pass
therethrough.
[0914] FIG. 112 illustrates another arrangement of a smoking
substitute system, in which the consumable has a single reservoir
for aerosol precursor which corresponds to the second storage
reservoir 110 in the embodiment of FIG. 108 In this arrangement,
the consumable does not have a flavor pod portion. For simplicity,
parts corresponding to those of FIGS. 108 to 111 are indicated by
the same reference numerals. Note that in FIG. 112, the support
wall 132 has multiple bores 134 therethrough, aligned with the
passages 136 in the heater support element 130.
[0915] FIG. 112 also shows the casings of the device. In
particular, there is a casing 300 (the "first" casing), being a
casing of the consumable 103. That casing contains the reservoir
110 for aerosol precursor, and also supports the wick support
element 120 and the wick 111. A tube 302 within that first casing
300 forms a bounding wall of the air-flow passage 108, and the
mouthpiece 109 is formed at an end of the first casing 300. The
main device 100 also has a casing 310 (the "second" casing) on
which are mounted the support wall 132 and the heater support
element 130. There is a space 312 within the second casing 310 for
a battery and other electronic components used to power the heater
112, and the second casing 310 may also have an inlet 314 to allow
air to enter the space 312 and hence pass to the bores 134 and the
passages 136 to enable it to reach the activation surface of the
wick 110.
[0916] FIG. 112 also shows electrical leads 138 which extend
through the support wall 132 and the heater support element 130 to
enable the heater 112 to be connected to a battery in space 312.
Small bores may be formed in the heater support element 130 and the
support wall 132 through which the leads 138 may pass. The first
and second casings 300, 310 are separable and held together by a
"click" engagement 316. When the two casings 300,310 are
interconnected, as shown in FIG. 112, the wick 111 is forced into
contact with the heater 112 by the resilience of the wick support
element 120, so that good heating of the activation surface of the
wick 111 will occur when the heater 112 is active. The separability
of the two casing 300, 310 allows the consumable 103 to be removed
from the main body 100, and replaced, e.g., when the aerosol
precursor in the reservoir 110 is exhausted.
[0917] FIG. 113 shows a perspective view of the consumable 103 in
FIG. 112, with the part of the first casing 300 removed so that the
wick 111 and the wick support element 120 are clearly visible. It
can be seen from FIG. 113 that the wick 111 is flat and so has a
planar activation surface (the exposed surface of the wick 111 in
FIG. 113). FIG. 113 also shows clearly the opening 124 in the wick
111, which allows communication with the passageway 126 through the
wick support element 120. The wick support element 120 in this
embodiment, and in some other embodiments, is preferably made of
rubber material. In a similar way, the wick 111 is preferably made
of silica material, which material is suitably porous to allow the
aerosol precursor to pass therethrough. Alternatively, the wick may
be of fibrous material, woven material or porous ceramic
material.
[0918] FIGS. 114 and 115 illustrate two alternative configurations
of a heater support element 130 which may be used in the present
disclosure. They differ in the shape of the mouth of the passage
136 through the heater support element 130 which allows air to pass
through the heater support element from e.g., the interior of the
casing of the main body 100 to the vicinity of the heater 112 and
the activation surface of the wick 111. Note that, in FIGS. 114 and
12, the heater itself is not shown and there is a single passage
134 through the heater support element 132. In each of the
alternative configurations, the heater support element 130 is
preferably made of resilient material, which must also be suitable
to resist the heat generated by the heater 112.
[0919] In FIG. 114, the heater support element 130 comprises a body
part 500 which has a peripheral seal surface 502 which seals to the
casing 310 (not shown in FIG. 114). The seal between the seal
surface 502 and the casing 310 needs to be sufficiently strong to
prevent, or at least significantly resist, movement of the heater
support element 130 in the casing 310, particularly when the
consumable 103 is removed from the main body 100.
[0920] A projecting part 504 projects from the body part 500,
terminating in a flat heater support face 506. The periphery of the
projecting part 504 seals to the casing 300 of the consumable 103,
and for this purpose may have ribs 508 on its side surface.
However, unlike the sealing of the seal surface 502 to the casing
310 of the main body 100, the sealing of the projecting part 504 to
the casing 300 of the consumable 103 needs to allow the consumable
103 to be removed to allow another consumable 103 to be mounted
thereon without too much resistance. Nevertheless, the sealing must
be sufficiently good to limit leakage of any aerosol precursor
which has passed through the wick 111 but has not been vaporized by
the heater 112. As in the arrangement of FIG. 112, the passage 136
passes through the heater support element 130 to enable air to pass
towards the heater 112 and the wick 111. In the heater support
element 130 shown in FIG. 114, the passage 136 terminates in a
splayed or funneled mouth 510, which opens into a slot 512 in the
heater support surface 506, so that air which has passed through
the bore 136 can expand in the funneled mouth 510 before reaching
the heater 112.
[0921] FIG. 114 also shows bores 514 through which pass leads from
the heater 112, which leads will provide electrical connection to
the battery.
[0922] The heater support element 130 shown in FIG. 114 is
resilient and is preferably made of silicone material, with
provision to resist high temperatures which may be generated by the
heater 112. For example, the material known as Polygraft HT-3120
silicone, which is a two-part mix, may be a suitable material from
which the heater support element 132 may be made. The configuration
shown in FIG. 114 will normally be made by molding the silicone
material in a suitable mold.
[0923] FIG. 115 illustrates an alternative heater support element
130. It is generally similar to the heater support element 130
shown in FIG. 114 and the same reference numerals indicate
corresponding parts. It may be made of the same materials as the
heater support element 130 of FIG. 114 The heater support element
130 of FIG. 115 differs from that of FIG. 114 in that the passage
136 opens directly into the channel 512 in the heater support
surface 506. There is thus a flat face 516 at the bottom of the
channel 516, rather than the funnel mouth 510 shown in FIG.
114.
[0924] FIG. 116 shows a heater that may be used with the heater
support element 130 shown in FIG. 114 or FIG. 115 The heater
comprises a heater filament 520 which is generally flat and rests
on the heater support face 506 of the heater support element 130.
For this reason, the filament 520 is not straight but meanders in
its plane. FIG. 116 also shows the leads 138 which extend through
the bores 514 of the heater support 130 shown in FIG. 114 or FIG.
115, to enable the heater 112 to be connected to a battery.
[0925] FIG. 117 illustrates an arrangement of a smoking substitute
system which incorporates the heater support element 132 of FIG.
114, and also the heater 112 of FIG. 117 The arrangement of FIG.
117 is generally similar to that of FIG. 112, and corresponding
parts are indicated by the same reference numerals. As mentioned
previously, when the heater support element 132 of FIG. 114 is
used, there is only a single bore 136 therein for air, hence there
is only a single bore 134 in the support 132 in the main body 100.
The bore 136 extends to the funneled mouth 510 which opens into the
slot 512 directly below the heater 112. Note that the leads 138 of
the heater 112 are not visible in FIG. 117.
[0926] FIG. 117 illustrates how the seal surface 502 of the main
body 500 seals to the second casing 310, and the projecting part
504 seals to the first casing 300. This sealing is illustrated in
more detail in the enlarged view of FIG. 118 In particular, the
first casing 300 of the consumable 103 extends sufficiently far
within the second casing 310 of the main body 100 so as to contact
the projecting part 504 of the heater support element 130 at a
sealing interface 518. Similarly, the main body 500 of the heater
support element 130 seals at a sealing interface 520 with the
casing 310 of the main body 100. As mentioned previously, the
degrees of sealing at these two sealing interfaces 518 and 520 are
preferably different, since the heater support element 130 does not
normally release from the second casing 310, but must release from
the first casing 300 when the consumable 103 is removed.
[0927] FIG. 118 also shows how the funneled mouth 510 of the
passage 136 opens within the heater support element 130 towards the
heater 112 and the wick 111. This causes the air flow from the
passage 136 to expand, as illustrated by the arrows 522, so that
there is a good air flow where the heater 112 meets the wick 111,
to entrain vapor therein prior to flow to the passage 126 in the
wick support element 120.
[0928] With the arrangement shown in FIG. 118, as in the other
arrangements, the sealing between the first casing 300 and the
heater support element 130 at the sealing interface 518 prevents
any leakage of aerosol precursor which has come from the wick 111
and has not been vaporized by the heater 112. Hence, when the
consumable 103 is fitted in place on the main body 100, the only
escape route for the aerosol precursor is via the airflow passage
108 and the mouthpiece 109. This helps to ensure efficient
consumption of the aerosol precursor.
[0929] The arrangement of FIG. 117 also differs from the
arrangement of FIG. 112 (and also that of FIG. 118), in that the
wick 111 extends across the whole of the end face of the wick
support element 120, as in the arrangement of FIG. 113 As before,
the wick 111 has an opening 124 therein to allow air to pass
through the wick 111 and into the passage 126, and hence through
the air-flow passage 108 so that it can reach the outlet 109 and
thus pass to the user.
[0930] FIG. 119 shows another arrangement of a smoking substitute
system, which is generally similar to that of the embodiment of
FIGS. 112 and 113 and corresponding parts are indicated by the same
reference numerals. In the embodiment of FIG. 119, however, there
is no heater support element 130, and instead the heater 112 is a
coil or other filament held within the second casing 310, which has
a space 400 adjacent thereto. The space 400 communicates with
inlets (not shown in FIG. 119) which allow air to enter the casing
310 and pass to the activation surface of the wick 111. Again, the
wick 111 is forced into contact with the heater 112 by the
resilience of the wick support element 120. In this arrangement,
the flow of air to the activation surface is not restricted by the
size of the passage or passages through the heater support element
130. In this arrangement the heater 112 needs to be sufficiently
stiff that it is not deformed when the wick 111 is urged into
contact therewith by the resilient wick support element 120.
[0931] In the arrangements of the smoking substitute system
described above, the wick support element 120 is a separate element
from the first casing 300 of the consumable 103.
[0932] FIG. 120 illustrates an alternative arrangement, in which
the wick support element is integral with part of the first casing
300.
[0933] In the arrangement of FIG. 120, parts which correspond to
arrangements described previously are indicated by the same
reference numerals. Note that, in FIG. 120, the main body 100 is
not shown. It may be the same as in the other arrangements of a
smoking substitute system described previously.
[0934] In the arrangement of FIG. 120, the first casing 300 has a
lower part 300a and an upper part 300b. The mouthpiece 109 is in
the upper part 300b, and the tube 302 is also integral with that
upper part 300b.
[0935] The lower part 300a has an upper rim which meets a lower rim
of the upper part 300b at a sealing surface 600, and has an
internal flange 602 adjacent its lower end. The internal flange 602
corresponds to the wick support element 120 of the arrangements
previously described. The internal flange 602 has a central bore
forming passage 126, which passage is aligned with the passage 108
within the tube 302. The end of the tube 302 furthest from the
mouth piece 109 engages the flange 602 and is sealed thereto.
[0936] The interiors of the upper and lower parts 300b and 300a of
the casing 300 are hollow, and form the reservoir 110. There are
bores 122 in the flange 602 to allow the reservoir 110 to
communicate with the wick 111, in the same way as the bores 122 in
the earlier arrangements described previously. Thus, aerosol
precursor in the reservoir 110 may pass through the bores 122 to
saturate the wick 111, and then be heated by the heater 112 (not
visible in FIG. 120). The arrangement of FIG. 120 prevents any
leakage of aerosol precursor between the wick support element 120
and the casing 300. Whilst there could be leakage between the upper
and lower parts 300b, 300a of the casing 300, this can be prevented
by suitable configuration of the sealing interface 600. However, if
the sealing of the reservoir 110 is too good, air may not be able
to enter it to replace aerosol precursor which has been
consumed.
[0937] Therefore, FIG. 120 shows that there may be at least one
additional bore 604 in the flange 602, to allow passage of air to
the reservoir 110 from outside the first casing. The or each
additional bore 604 needs to be sufficiently small that it will not
allow a significant amount of aerosol precursor to pass
therethrough. For example, the or each additional bore 604 may be
e.g., 0.2 to 0.5 mm in diameter, more preferably 0.32 to 0.5 mm,
even more preferably 0.32 to 0.4 mm. If the flange has a thickness
of e.g., 0.5 to 5 mm, preferably 1 to 5 mm, aerosol precursor
should not be able to escape reservoir 110 through the or each
additional bore 604. In general, the thicker the flange 602, the
greater the possible diameter of the or each additional bore 604
may be, without it allowing aerosol precursor to flow therethrough.
A thin flange 602 (which thinness may be desirable for manufacture)
will thus need the diameter of the or each additional bore to be
small.
[0938] The upper and lower parts 300a, 300b of the casing 300 may
be separable to allow for refiling of the reservoir 110 once the
aerosol precursor wherein has been consumed. In such an
arrangement, the sealing at the sealing surface 640 needs to be
sufficiently good to prevent leakage of aerosol precursor
therethrough when the smoking substitute system is in use.
Alternatively, the seal at the sealing surface 600 may be a
permanent one, with the upper and lower parts 300a and 300b if the
casing bonded together. In such an arrangement, the reservoir 110
may not be refillable, and the consumable 101 would need to be
replaced once the aerosol precursor in the reservoir 110 had been
consumed.
[0939] In the arrangements described previously, the bores 122 in
the wick support element 120 (or in the flange 602 in the case of
FIG. 120) were described as being sized so that aerosol precursor
may flow therethrough in a non-capillary manner. In an alternative,
applicable to all the arrangements described previously, the bores
122 may be capillary ducts (hereinafter referred to as capillary
bores) which allow aerosol precursor to flow therethrough in a
capillary manner. The capillary bores allow the flow of aerosol
precursor to the wick 111, in a controlled manner, so that there is
less chance of there being excess aerosol precursor at the wick
111. In general, the capillary bores may have a diameter range of
0.3 mm to 2 mm, as a diameter of less than 0.3 mm will generally
not allow sufficient aerosol precursor to pass to the wick 111.
Preferably, the diameter is at least 0.5 mm, preferably 0.8 to 1.5
mm, and more preferably 1 mm or 1.3 mm. In practice, the diameter
of the capillary bores may be affected by the thickness of the wick
support element 120, which can have a thickness of e.g., 0.5 mm to
5 mm, more preferably 1 to 5 mm, such as 4 mm, 3 mm, 2 mm and 1 mm.
In general, the width of the capillary bores will need to be
greater with greater thickness of the wick support element 120.
[0940] In the arrangements of FIGS. 109 to 119, the wick support
element 120 is made of resilient material such as rubber. In the
arrangement of FIG. 120 on the other hand, the support for the wick
111 is rigid, because it was formed by the internal flange 602
which was integral with, and therefore made of the same material
as, the casing 300. FIGS. 121 and 122 then illustrate another
arrangement in which the wick is supported by a rigid element.
Unlike the arrangement of FIG. 120, however, in the arrangement of
FIGS. 121 and 122, that rigid element is a separate wick support
element 720. In FIGS. 121 and 122, parts which correspond to parts
of earlier arrangements are indicated by the same reference
numerals. Moreover, as in FIG. 120, only the consumable 103 is
illustrated. The main part 100 may be the same as in earlier
arrangements.
[0941] In particular, in the arrangements of FIGS. 121 and 122, the
rigid wick support element 720 is formed at an end of the reservoir
110, within the first casing 300. Bores 122 through the wick
support element 720 allow aerosol precursor from the reservoir 110
to pass to wick 111. Whilst the bores 122 may be non-capillary
bores, they are preferably capillary bores. The diameter of the
capillary bores may be as previously described, as may the
thickness of the wick support element 720. Although not illustrated
in FIGS. 121 and 122, there may need to be an additional bore or
bores in the wick support element 720 to allow passage of air to
the reservoir 110, corresponding to the at least one additional
bore 604 in FIG. 120.
[0942] In order to prevent escape of liquid from the reservoir, the
wick support element 720 is preferably sealed to the first casing
300 by seals 610. For example, the seals 610 may be O-ring seals
extending around the wick support element 120. The seals can be
seen clearly in FIG. 122, as can the opening 124 in the wick 111,
which leads to the passage 126 through the wick support element 720
to the air-flow passage 108. The wick support element 720 also
needs to be sealed to the tube 302, to prevent escape of aerosol
precursor from the reservoir 110. To achieve this, the wick support
element 720 may have an upstanding ring 612, which then seals
(e.g., by O-rings and/or an interference fit) to the tube 302.
Grooves for those O-rings are illustrated in FIG. 122 Another
possibility is for the tube 302 to be integral with the wick
support element 720, with the end of the tube 302 being sealed to
the casing 300 adjacent the mouthpiece 109.
[0943] The rigidity of the wick support element 720 and the tube
302 means that the positioning of the wick support element 720 on
the tube 302 and the positioning of the tube 302 relative to the
casing 300 may be determined to good precision. This ensures that
the wick 111 is accurately positioned relative to the casing 300,
and hence accurately positioned relative to the casing 310 and the
heater 112.
[0944] In the arrangement of FIGS. 121 and 122, the wick support
element 720 may be made of the same material as the casing 300 (and
the casing 310) such as being made from molded polypropylene
plastics material. Other suitable materials to form the wick
support element 720 include ABS and PEAK materials. The seals 610
may be O-rings of e.g., rubber material or silicone seals co-molded
with the wick support element 720, but preferably are nitrile or
thermoplastic polymer O-ring seals. The molding of the wick support
element 720 and the first and second casings 300, 310 simplifies
manufacture.
[0945] Because the wick support element 720 is rigid in the
arrangement of FIGS. 121 and 122, it may be thinner than the
resilient wick support elements 120 described with reference to
e.g., FIGS. 108 to 119. Thus, it may then be possible to have a
wick support element 720 with a thickness of e.g., 0.5 to 2 mm,
preferably 1 mm, allowing the bores 122 to have a small diameter,
and still provide a capillary effect. The same is true in the
arrangement of FIG. 120 Thus, at least in the arrangements of FIGS.
120 to 122, the bores 122 may have a diameter of 0.3 mm to 2 mm,
most preferably 0.5 mm. If one or more additional bores are
provided, corresponding to the additional bores 604 in the
arrangement of FIG. 121, to allow air to enter the reservoir volume
to replace aerosol precursor which has passed to the wick 111,
those additional bores will have small diameters, due to the
reduced thickness of the wick support element 720, so e.g., less
than 0.3 mm. The diameter of the additional bores will always be
less than the diameter of the capillary bores. It should be noted
that, even in the arrangements of FIGS. 108 to 119, it may be
possible to have small diameter capillary bores, if the wick
support element 120 is thin enough.
[0946] In the arrangements of FIGS. 120 to 122, the position of the
wick 111 is precisely determined, relative to the casing 300,
either because the wick support element is part of the casing
itself, as in the arrangement of FIG. 120, or because the position
of the wick support element 720 is determined by a component of the
casing such as the tube 302, as in the arrangement of FIGS. 121 and
122. This precise positioning of the wick 111 in the casing 300
means that manufacture will be consistent and hence replacement of
one consumable with another will not alter the relationship between
the wick 111 and the heater 112, and so will not affect the
efficiency of the smoking substitute device.
[0947] The use of capillary bores 122 in the wick support element
720 in the arrangements of FIGS. 120 to 122 mean that it is
possible to optimize the flow of aerosol precursor to the wick 111
to minimize leakage.
[0948] The length and diameter of the capillary bores 122 may be
chosen to control the flow of a specific aerosol precursor
formulation to the wick 111, based on the viscosity and liquid
characteristics of that aerosol precursor. When aerosol precursor
is vaporized from the wick 111 by the heater 112, there will be an
available volume of air in the wick 111 allowing additional aerosol
precursor to flow into the wick 111, so that the wick 111 is
maintained in a saturated state when the device is in use. The
rigid nature of the wick support element 720 improves the
consistency of liquid flow to the wick 111, compared to a wick
support element 120 of resilient material, so that efficient
operation may be achieved.
[0949] The sealing configuration in the arrangement of FIGS. 121
and 122 makes use of O-rings, with the effect of minimizing leakage
in use and in transit, as a robust seal is created between the wick
support element 720 and the casing 300, so that there is no leakage
path therebetween. O-ring technology is well established, so it is
straight forward to put in to practice in the smoking substitute
device to reduce or eliminate variation between parts, improving
repeatability of manufacture.
[0950] The use of a rigid wick support element 720 in the
arrangements of FIGS. 120 to 122 means that the wick support
element 720 is easy to manufacture with high precision, and the
assembly of the consumable may easily be automated. This ensures
efficient manufacture, thereby reducing costs.
[0951] The features disclosed in the foregoing description, or in
the following claims, or in the accompanying drawings, expressed in
their specific forms or in terms of a means for performing the
disclosed function, or a method or process for obtaining the
disclosed results, as appropriate, may, separately, or in any
combination of such features, be utilized for realizing the
disclosure in diverse forms thereof.
[0952] While the disclosure has been described in conjunction with
the exemplary embodiments described above, many equivalent
modifications and variations will be apparent to those skilled in
the art when given this disclosure. Accordingly, the exemplary
embodiments of the disclosure set forth above are considered to be
illustrative and not limiting. Various changes to the described
embodiments may be made without departing from the spirit and scope
of the disclosure.
[0953] For the avoidance of any doubt, any theoretical explanations
provided herein are provided for the purposes of improving the
understanding of a reader. The inventors do not wish to be bound by
any of these theoretical explanations.
[0954] Any section headings used herein are for organizational
purposes only and are not to be construed as limiting the subject
matter described.
[0955] Throughout this specification, including the claims which
follow, unless the context requires otherwise, the word "comprise"
and "include", and variations such as "comprises", "comprising",
and "including" will be understood to imply the inclusion of a
stated integer or step or group of integers or steps but not the
exclusion of any other integer or step or group of integers or
steps.
[0956] It must be noted that, as used in the specification and the
appended claims, the singular forms "a," "an," and "the" include
plural referents unless the context clearly dictates otherwise.
Ranges may be expressed herein as from "about" one particular
value, and/or to "about" another particular value. When such a
range is expressed, another embodiment includes from the one
particular value and/or to the other particular value. Similarly,
when values are expressed as approximations, by the use of the
antecedent "about," it will be understood that the particular value
forms another embodiment. The term "about" in relation to a
numerical value is optional and means for example +/-10%.
[0957] The words "preferred" and "preferably" are used herein refer
to embodiments of the disclosure that may provide certain benefits
under some circumstances. It is to be appreciated, however, that
other embodiments may also be preferred under the same or different
circumstances. The recitation of one or more preferred embodiments
therefore does not mean or imply that other embodiments are not
useful, and is not intended to exclude other embodiments from the
scope of the disclosure, or from the scope of the claims.
* * * * *